[chicagobob]

Got the Yoshi exhaust. Another 8 lbs off. Impressions: Not much louder than stock, but much deeper and more motorcycle-ish. I'm running the DB-reducing insert. Increases peg vibes a little, but that might be due to my cut-down peg brackets.

 

[theSLEEPER]

I'm torn between keeping my lower fairing or not. I really like the way yours looks without it. Love the whole bike.

 

[chicagobob]

I'm torn between keeping my lower fairing or not. I really like the way yours looks without it. Love the whole bike.

It seems the chin fairing's only function is to hide the ugly exhaust can, so if you have an aftermarket exhaust, you may not want it.

 

[theSLEEPER]

I just installed a turn-out on the exhaust. So I took the fairing off, and I like it so far. I'm not sure about the straight exhaust quite yet, so we'll see.

 

[MarktheShark]

WoW Looks Great!

So how much weight total do you think you removed? I guessing it's close to 50lbs. I think mine is around 30 something lbs lighter and it was a noticeable change in handling and acceleration. I'm 6'1" and 230lbs so any weight savings would be noticeable to me.

Keep us updated on how you like that rear shock, I'm somewhat torn between the one you chose and the YSS shock.

 

[HamMan650]

Cant wait to get those side fairings

 

[chicagobob]

WoW Looks Great!

So how much weight total do you think you removed? I guessing it's close to 50lbs. I think mine is around 30 something lbs lighter and it was a noticeable change in handling and acceleration. I'm 6'1" and 230lbs so any weight savings would be noticeable to me.

I counted 47 lbs - 64 removed and 17 added back (headlight, exhaust, battery, peg brackets, turn signals), but I haven't been able to weigh the bike yet. Not much chance to even ride this week. 18 degrees with snow forecast.

 

[HilbillyKat]

Looks great Bob. But if I were you..I would take the seat to someone that could sculpt it into a more supportive saddle shape..with a little more foam. Just a thought.

 

[bran077]

Looks great Bob. But if I were you..I would take the seat to someone that could sculpt it into a more supportive saddle shape..with a little more foam. Just a thought.

+1

Looks aside, you want to enjoy the ride. I was thinking they would probably be able to angle the seat more into the tank to solve that fitment problem as well.

 

[simsim]

very, VERY cool!

 

[jam]

awesome build i want to find a650r to do like yours !

 

[Napkin Legend]

I honestly couldn't tell you how much I've lost in weight. The belly pan will probably come off soon too. Then I've got to add about 10 pounds after swapping to the 180 wheel and adding various brackets. I also have to get the exhaust can back on after it's done being brushed.

 

[chicagobob]

I made a few changes recently, in preparation for making a new seat, and shaved another pound off the beast. I was happy with my original idea of locating the coolant recovery tank in the battery box, but after I removed the stock exhaust, I had room for the tank around the front part of the swingarm, since there was no longer a muffler under that area to overheat the tank and its hoses. This allowed me to stuff the Ballistic battery, the ECU, and most of the wiring into the battery box, which moved that weight lower in the bike, allowed shorter, lighter battery cables, and removed the need for the heavy stock ECU mounting bracket. The Power Commander fits under the fuel pump, and everything is now more centrally-located and closer to the ground. I also have a free hand to design a new seat and tail section. I'll let you know how that comes out.

In the meantime, here are some pics of the change:

The coolant tank in the swingarm. It's an aftermarket rectangular 16-oz container with a molded-in nipple on the bottom. It came in white with mounting tabs, which I cut off for this application. It's almost exactly the size of the stock battery, and so fit nicely in the battery box (I guess that means that the stock battery would also fit nicely in the swingarm, but that would raise a few other issues)

You can also see here how the rear brake fluid reservoir clamps onto the brake line:

The view from underneath the swingarm. The coolant tank is a wedge fit, but I riveted an aluminum bracket underneath for extra security:

The new rat's nest. The battery and ECU are under there somewhere. The important thing is that nothing projects above the top of the frame rails, so I can use part of the stock seat pan:

Now there's lots of room under the tail section. The square black thing is the controller for the heated grips. The relay can be seen under the left side of the fuel tank mounting bracket:

Power commander peeking out from under the tank. Grip heater relay to the right of the tank bracket in this photo:

 

[kojiiro]

What's yur bike weigh now?

 

[Ozninjaguy]

I really like what you have done. Looks awesome - talented guy - plz post a completed pic with new pipe...

 

[chicagobob]

I really like what you have done. Looks awesome - talented guy - plz post a completed pic with new pipe...

Here's a couple of recent pix:

 

[LoganG]

The bike looks really really good! A lot different than all the 650s out there.

 

[chicagobob]

Over the last few weeks, I've made a new seat for my lightened '09. I wanted to improve the look of the front of the seat, where it wraps around the tank, return to the softer foam of the stock seat, and to lighten the bike even further. I also wanted a simpler taillight and license plate mount.

I had previously relocated all the components that had been under the seat cowling, so I had a free hand with the design. I made an entirely new aluminum base, a plywood and fiberglass seat pan, foam cushion, and cowling. The Legendary molded foam pad was not uncomfortable, but it was so firm that it transmitted a lot of road and engine vibration.

The new seat is 3.5 lbs lighter than the one I had before. I made it by using the front part of the stock seat pan, fiberglass-coated plywood, the stock foam (recountoured), and part of the stock seat cover. The cowling is part of the original Legendary Motorcycles Phat Tail seat pan. Some pics:

Here's the frame with everything relocated forward (into the battery box and under the tank)

The new "fender," which is riveted to the frame. Its sole purpose is to shed water and act as a place for a hold-down for the back of the new seat. It's 1/16" aluminum plate:

The new seat pan coming together on the bench:

Test fit: Not bad, but I'll need new tank panels:

New fender/taillight/license mount. It's a thinner piece of metal bent and riveted to the pan and battery box:

The finished product, with the new tank panels:

A closer look in the garage (it was 5 below zero this morning):

 

[rcannon409]

Great bike. With regards to the rear fluid reservoir, you know you dont REALLY need it. You probably knwo this , but for anyone else.

I'll explain. Its function si to store extra fluid. As the pedal is pressed, the pads contact the rotor. Over time, this wears the pads down, they go in further, and more fluid is needed to make up the difference. The system is pretty much designed so that there will be enough spare fluid in the reservoir to handle the entire lifespan of the brake pads. So, if your adding fluid, your pads are probably shot.

You can order this HRC kit. Honda has used this, for may years, on its racing bikes. ROGUE RACING CBR1000RR Rear M/C Reservoir

Or, a trip to the hardware store for a piece of tubing, and cap.

Maybe nto the perfect accessory for a touring motorcycle, but excellent for this bike. Only drawback si havign to top off this little tube more often.