What other bits needed when going from steel to alloy frame?

Message

s4oz · #1 Post by **s4oz** » Mon Jan 30, 2012 3:32 am

Hi all

Feeling pretty excited and a bit nervous over here - just bought an alloy RZVR frame to replace my steel RZ one.

I believe it will only be a bare frame and there are several bits I will need to purchase or have fabricated or modified from the old steel bike.

My searches in the forum have found many threads mentioning various items (1 or 2 swing arm pivots, engine mounts, frame brackets and others too), but I would really like one complete list. It would drive me nuts to start pulling everything apart and have to stop for weeks while I find "that" missing bit I didn't know I needed.

Can someone help me with a list of what I will need and possibly where I could find such bits?

P.S. I have just realised that my frame S/N starts with 53G and the alloy one I bought starts with 51G - someone please tell me the conversion is possible and the frame, aside from brackets etc can be reasonably easily swapped out?

RZVTokyo · #2 Post by **RZVTokyo** » Mon Jan 30, 2012 10:05 am

Hi,

If you're switching to an RZV frame from a steel frame you'll need the following for the basic conversion:
-RZV shock linkage bolt (the one that bolts the linkage to the frame)
-RZV lower engine mounts (they bolt on to the RZV frame)
-RZV battery box bracket
-RZV swingarm pivot bolt

If you're planning to do a full conversion, there are also the following parts involved:
-RZV mirrors
-RZV allow handlebars
-RZV fuel tank with fuel level sensor
-RZV gauges (speedo, tach and temp/fuel level gauge)
-RZV main and sub harness (you may be able to modofy your existing harness)
-RZV front forks
-RZV rear shock
-RZV upper fairing bracket (you can modify your existing bracket)
-RZV RH handlebar switch (this switch controls the fuel level gauge)
-RZV LH handlebar switch ( the RZV unit has a highlight switch for passing)
-RZV alloy brake and shifter levers

I hope this helps

LC Boy · #3 Post by **LC Boy** » Mon Jan 30, 2012 7:08 pm

Q. RZV rear shock??? Is there a difference between RD RZV RZ if yes what???

rklages · #4 Post by **rklages** » Mon Jan 30, 2012 10:14 pm

LC Boy wrote:Q. RZV rear shock??? Is there a difference between RD RZV RZ if yes what???

I have one here, looks quite different and uses a lot of aluminum in the construction instead of steel. I can send you a pic of it if you send me your email.

Rob

s4oz · #5 Post by **s4oz** » Mon Jan 30, 2012 11:53 pm

RZVTokyo - thank you - that is the definitive list, extremely appreciated.

I wonder if RZTom should consider making it sticky?

I hope you don't mind me asking you and anyone else able to offer some insights, a few more questions.

- of the essential 4 parts for a basic conversion, where can I look for them, Japan again? Or is it easier to just look for someone to fabricate them in Australia? I have kept an eye on Yahoo Japan, but they don't seem to come up with individual items like this... any suggestions much appreciated.

- In the "full conversion" list you mention main and sub harness - I presume this is the electrical loom? If so, I'm cool as my conversion is just the frame, no fuel tank/sensor etc.

- RZV upper fairing bracket (you can modify your existing bracket) - is it an easy mod?

- I have a 53G steel frame and have purchased a 51G alloy one. Are there big differences and if so what rework will be needed?

RZVTokyo · #6 Post by **RZVTokyo** » Tue Jan 31, 2012 12:56 am

As for the upper fairing bracket is concerned, the RZV has a wider mounting point for it on the frame. You'll need to remove the small welded on spacers on your RZ fairing bracket to fit the wider RZV frame.

If you're interested, I do have some RZV spares. I'll see what I've got and can send you photos if you send me your email address.

As for the rear shock, the RZV has an aluminum-bodied shock. The RZ's shock is steel.

RC45 · #7 Post by **RC45** » Tue Jan 31, 2012 1:33 am

Or take the chance to switch to an Ohlins unit.

s4oz · #8 Post by **s4oz** » Tue Jan 31, 2012 2:44 am

RZVTokyo wrote:As for the upper fairing bracket is concerned, the RZV has a wider mounting point for it on the frame. You'll need to remove the small welded on spacers on your RZ fairing bracket to fit the wider RZV frame.

If you're interested, I do have some RZV spares. I'll see what I've got and can send you photos if you send me your email address.

As for the rear shock, the RZV has an aluminum-bodied shock. The RZ's shock is steel.

PM sent, cheers.

Not interested in Ohlins unit at this stage, just the various pivots, etc.

Stefan

RC45 · #9 Post by **RC45** » Tue Jan 31, 2012 2:54 am

It appears one can use the RZ/RD swingarm pivot bolt.

From my notes of a conversation with RGVSteve, the RZV bolt is 316mm long, 295.8mm of shaft, some taper and then 17mm of thread.

So it appears that extending the thread of the RZ/RD bolt will alloy it to be used on an RZV frame.

At least this is what I will trying to do once I get the RZ/RD bolt out of my steel frame.

rd84 · #10 Post by **rd84** » Tue Jan 31, 2012 11:13 am

If you're switching to an RZV frame from a steel frame you'll need the following for the basic conversion:
-RZV shock linkage bolt (the one that bolts the linkage to the frame)
-RZV lower engine mounts (they bolt on to the RZV frame)
**-RZV battery box bracket
-RZV swingarm pivot bolt

If you're planning to do a full conversion, there are also the following parts involved:
-RZV mirrors
**-RZV allow handlebars
**-RZV fuel tank with fuel level sensor
**-RZV gauges (speedo, tach and temp/fuel level gauge)
**-RZV main and sub harness (you may be able to modofy your existing harness)
**-RZV front forks
**-RZV rear shock
-RZV upper fairing bracket (you can modify your existing bracket)
**-RZV RH handlebar switch (this switch controls the fuel level gauge)
**-RZV LH handlebar switch ( the RZV unit has a highlight switch for passing)
**-RZV alloy brake and shifter levers

Hi,
If you are not trying to do a perfect RZV replica I would think that you could miss off the above items that I have put a ** next to ?
Cheers
Paul

Andrew · #11 Post by **Andrew** » Tue Jan 31, 2012 12:07 pm

... and mirrors.

s4oz · #12 Post by **s4oz** » Wed Feb 01, 2012 9:45 am

Thanks for all the replies guys, most appreciated.

What is likely to be simpler and less expensive (and quicker): search for the list of bits or have them fabricated by my shop?

I only need the bits so motor and fairings and original swing arm will fit, not interetsed in Jap front end as I have an FZR Exup front end ready to go in. Having a tank with a low fuel sensor is also of no interest.

Cheers.

Stefan

RZVTokyo · #13 Post by **RZVTokyo** » Wed Feb 01, 2012 11:06 am

I forgot to mention...
You'll also need the RZV side stand upper bracket (the stand portion and spring are the same as the RZ/RD units)

RC45 · #14 Post by **RC45** » Wed Feb 01, 2012 11:20 am

RZVTokyo wrote:I forgot to mention...
You'll also need the RZV side stand upper bracket (the stand portion and spring are the same as the RZ/RD units)

Side stands? We don't need no stinkin' sidestands... thats what pub walls are for

s4oz · #15 Post by **s4oz** » Wed Feb 01, 2012 6:52 pm

Well, I thought as much too, but I am not sure right now if I will end up with a racer for Period 6 Post Classic events here in Australia or a club registered bike for weekend blasts and the odd ride day.

I'm putting a bet each way as I have both original bodywork and fibreglass replica (currently unpainted). The wiring loom has been removed in good part, but it can be clipped back in. The rest will work on track or road.

Still keen to hear opinions on fabricating necessary bits Vs tracking them down and buying them....

500 Two-Stroke Tech

What other bits needed when going from steel to alloy frame?

What other bits needed when going from steel to alloy frame?

Rear shock

Re: Rear shock