R&D: 17" Rear Wheel Swap (RF600/Bandit 600)

Maintenance, repair, troubleshooting, etc.
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pdworak
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Motorcycles Owned Currently: 1993 Yamaha Seca II

Wed Sep 16, 2015 3:07 pm

OEM Kawasaki spacer cost me $18 (NOS including shipping). Chunk of SS bar stock long enough to machine one out of would be at least that much plus my time to fool with it. I'd probably have to buy a min. 8' length for about $200. Aluminum is too soft for the seal to run on and also not cheap. Steel would have cost less, maybe even free as we have scrap bar stock in house, but I would have to get it plated. It's always cheaper to simply buy a ready made production part rather than trying to recreate it from scratch.

Radare's picture looks like the caliper can easily move 1 mm inboard so the Seca 13 mm spacer may work. I ordered the caliper yesterday so I'll test fit next week.

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Casper
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Thu Sep 17, 2015 6:16 am

1' of 1.25" 303 stainless - $32
1' of 1.25" 304 stainless - $32
1' of 1.25" 316 stainless - $40

MetalSupermarkets.com

1' of 1.25" 303 stainless - $25
1' of 1.25" 304 stainless - $25
1' of 1.25" 316 stainless - $35

http://www.onlinemetals.com

1' of 1.25" 303 stainless - $36
1' of 1.25" 304 stainless - $14
1' of 1.25" 316 stainless - $41

http://www.speedymetals.com

I'm sure you can find smaller stock for cheap. The major cost (once you have the machine and tooling) in making these spacers is a little bit of time, but you will spend that time anyways in modifying the brake caliper bracket.
Men do not quit playing because they grow old; they grow old because they quit playing.

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Firebolt
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Motorcycles Owned Currently: 00', Yamaha XJ 600
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Thu Nov 12, 2015 10:23 am

Hello everybody !
I come to you about the 600 bandit phase 2 rear wheel swap. My father and I had a lot of work to finish the cafe racer project (I currently created an topic about it) and that’s why I didn’t have the time to writed about the rear wheel swap.
So, the most important thing is that the 600 bandit phase 2 (2000 to 200…5 ?) rear wheel can be fixed on our 600 XJ swingarm (such as 600 bandit phase 1 rear wheel in the Radare’s topic).
However, we don’t have the same spacer dimensions that Radare, particularly with the bearing spacer and the rear brake support spacer
Now little picture (sorry for the poor quality of the scheme, have not the time to realize it on SolidWorks) to describe this modifications :

Image

1) Wheel axle (De = 17mm)
2) Swingarm
3) Spacer (Di = 17mm, De = 35mm, e = 19mm)
4) XJ600 Rear brake caliper support
5) Spacer (Di = 17mm, De = 32mm, e = 2,8mm)
6) XJ600 spacer
7) Wheel bearing (Di = 17mm)
8) Bearing spacer (Di = 17mm, De = the same that XJ600 origin axle, L = 89mm)
9) 500GSE sprocket support
10) Sprocket spacer (the same that Radare, e = 3mm)
11) Sprocket (for me 49 tooth at the rear and 16 for the front)
12) Spacer (Di = 17mm, De = 28mm, e = 14mm)

BUT :
- We don’t have modified the rear brake caliper support of the XJ600 (100% origin)
- We have made a new rear brake caliper renforcing bar (As you can see on pictures)
- 600 bandit bearings are the same that Radare has used on his topic (so 600 bandit rear wheel phase 1 or 2 have the same axle diameter, but not the same lenght (different bearing spacer). Such as Radare, we are re-used the 17 mm diameter axle

Some photos :

Image

Image

Image

Image

Image

Conclusion :
After more than 1300 km (800 miles) in less than 4 weeks, the motorcycle have not problem, just I am suprised about the sensibility of the rear brake pedal. I don’t have ride with an origin XJ600 beacause the project has been started when I bought the bike, so I don’t know…
When I brake with the rear pedal I often block the rear wheel (and you imagined how much it’s dangerous, especially one time on the wet road…) But on the other hand I tell myself it’s possible that situation is normal because I passed my driving licence on ABS motorcycle…
And you, are you already block the rear wheel on your XJ 600 ?

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Casper
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Thu Nov 12, 2015 9:19 pm

Locking the rear wheel is easy, take it easy on the brakes and find that sweet spot just before lock up. ABS should prevent most if not all lock ups and allow you to drive it like a car, don't do that on the bike...
Men do not quit playing because they grow old; they grow old because they quit playing.

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Firebolt
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Sat Nov 14, 2015 6:17 am

Casper wrote:Locking the rear wheel is easy, take it easy on the brakes and find that sweet spot just before lock up. ABS should prevent most if not all lock ups and allow you to drive it like a car, don't do that on the bike...
Yes this is what I think too ;)

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pufferfis
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Sat Sep 17, 2016 11:20 pm

I need a bit of advice...i have a gsf 400 17'' rear wheel 4.0 sized lying around and its fitted with a rotor which is 4 bolts and 250mm in diameter and would like to fit size 140/70 sized tyres as these are pretty cheap and plentiful in this part of the world.
1) Would the 250mm diameter rotor edge rubbed against the xj600 brake caliper as this rotor would extend 2.5mm above the brake pads as the original rotor is 245mm as mentioned by radare?This is assumed if we use radare plan of using the original xj600 brake caliper setup?
Hope to hear your thoughts?

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radare
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Tue Oct 04, 2016 1:15 am

pufferfis wrote:I need a bit of advice...i have a gsf 400 17'' rear wheel 4.0 sized lying around and its fitted with a rotor which is 4 bolts and 250mm in diameter and would like to fit size 140/70 sized tyres as these are pretty cheap and plentiful in this part of the world.
1) Would the 250mm diameter rotor edge rubbed against the xj600 brake caliper as this rotor would extend 2.5mm above the brake pads as the original rotor is 245mm as mentioned by radare?This is assumed if we use radare plan of using the original xj600 brake caliper setup?
Hope to hear your thoughts?
There is enough clearance to use the Suzuki rotor with the XJ caliper. But it will wear a groove in the top of your rotor. If possible, you should use the Suzuki rotor and caliper together (the Suzuki caliper is lightyears better than the XJ caliper in terms of feel).

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pufferfis
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Motorcycles Owned Currently: 92 Yamaha Seca 2,05 Suzuki GSF650,07 Raider150

Thu Jun 08, 2017 2:15 am

Hi again Radare... I just found out that the gsf400 rear wheel uses a wheel spacer which is 78mm long compared the bandit 600's 97mm long spacer thus there is an extra 19mm needed to be filled by spacers and im not reli that mechanically good to find out what spacer need to be what length.........
i know nuts about measuring spacers and what not so i guess I will just stick to follow your bandit wheel conversion to the letter...

I have just one question....is the bandit 600/RF600 wheel able to fit 140/70 tyre sizes?...I read up on some websites which said that the 4.5'' rim can fit tyre sizes from 160/60 to 150/70 to 150/60 to 140/70.... Is that true?I just wanna know my options thats all...

I have got most of the items except for the rear wheel and brake caliper and right spacer...a slow process to the conversion....cheers

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