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XJ550R front end replacement - brakes.

This is a discussion on XJ550R front end replacement - brakes. within the Technical forums, part of the Caferacer.net Forums category; hi kenessex, saw a few pictures of you bike throughout the web, have to say i just love it! thanks for the answers, i will ...

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  1. #21
    Senior Member Ravivos's Avatar
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    hi kenessex,
    saw a few pictures of you bike throughout the web, have to say i just love it!
    thanks for the answers, i will look into a 17" front wheel as well.
    in parallel, i will try to find out what spacer size i need in order to fit the 320mm rotors, and what bushing size i need to make to fit the XJ550 wheel on the R6 front (bushing, bearings... the works).

  2. #22
    Senior Member Ravivos's Avatar
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    finally got the parts it the mail, man... sea freight takes forever.
    here are some notes for future reference -
    the XJ550 steering bearing OD are 48mm
    the R6 stem is 31mm for the lower bearing and 30mm for the upper bearing.
    since there is no bearing that is 31x48, i decided to lath the stem to be able to accept a 30mm bearing for the bottom one...
    already ordered new tapered bearings for AllBalls, at 30x48x12 and 30x48x15, will probably need to have some sort of a spacer under the bottom bearing in order to clear the lower tree from the neck.
    once this is done, we can move on to fitting the XJ550 front wheel onto the R6 front.

    some notes on the wheel -
    R6 front axial diameter - 22mm
    XJ550 wheel bearing OD - 42mm
    unfortunately , this is not a standard bearing and i had to order a special one from abroad as i couldn't find any here in Israel, it is 6004/22 (22x42x12).
    found that the FZR1000 rotors have the same bolt pattern as the XJ550 wheel, so it should bolt right on, it is a 320mm rotors so i will have to adjust my calipers to accept the new rotors (radial brakes, should be easy).
    need to finish making the proper length bushing, and we are done.

    once it is all in place, i need to come up with an idea on a proper speedometer that wont look funny on an old bike.

    any comments are welcomed.
    Ravivos.

  3. #23
    Senior Member steveo's Avatar
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    "It's better to keep your mouth shut and appear stupid than to open it and remove all doubt"

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  5. #24
    Senior Member hillsy's Avatar
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    I used that Acewell on my ZX9 streetfighter and it was flawless.

    I did end up putting the original instruments back on the bike to sell, so I still have it for a future project

  6. #25
    Senior Member steveo's Avatar
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    Quote Originally Posted by hillsy View Post
    I used that Acewell on my ZX9 streetfighter and it was flawless.

    I did end up putting the original instruments back on the bike to sell, so I still have it for a future project

    Agreed the Acewell looks neat.

    BTW Hillsy... Don't you ever sleep?
    Last edited by steveo; 02-16-2015 at 04:36 PM.
    "It's better to keep your mouth shut and appear stupid than to open it and remove all doubt"

  7. #26
    Senior Member Ravivos's Avatar
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    Hi Stevo , hillsy... thanks, as usual, your info is right on the money.

  8. #27
    Senior Member Ravivos's Avatar
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    just a quick update -
    had to lath the R6 stem to accept a 30mm ID bottom bearing, the R6 stem is 30mm to, 31mm bottom...
    bought the allballs 30x48 bearings (12mm and 15mm) that fitted great on the milled stem.

    had a little problem, since the R6 front axle is 22mm, and the XJ550 wheel bearing OD is 42mm, the only bearing that will fit does not have the proper strength that is needed (comparing to the original one, the 42x22 bearing is 30% weaker)
    decided to use a different front shock absorbers (that i had) off an 1996 Suzuki RGV, they will more adequate with the stripped down XJ550 weight and uses a 17mm axle, so no problem using a 17x42x13mm bearing.

    the RGV front brakes are 300mm based on a non-radial nissin calipers, so decided to find a 300 mm rotors that will fit the bolt circumference of the XJ550... found that the TDM850 will fit.
    next thing is to make two spacers that will locate the rotors in the middle of the calipers, measurements shows i will need to make a 14mm thick spacer with the proper holes to get both rotors outwards to fit the calipers.

    will post some photos shortly.

  9. #28
    Senior Member Ravivos's Avatar
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    some pics -
    R6 triple tree with machined down steering axis from 31mm to 30mm
    RGV500 suspensions.
    TDM850 dual rotors.
    nissin calipers and master cylinder.
    Had to machine some bushings in order to center the wheel... will have to find a way to get a speedo working, will probably use a digital one that counts the wheel's rotation.
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  10. #29
    Senior Member Ravivos's Avatar
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    still need to find a way to mount the front fender properly .

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