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ex650 track bike weight loss program

23K views 49 replies 9 participants last post by  Mevanski 
#1 ·
I'm looking to build a new track bike this winter and I feel the 650 is a good platform to start with. The question I have is, when the race fairings are in place, the battery is swapped for lithium, and the tubby exhaust is swapped for an Arrow unit, what's the rough finished weight for you guys that have done the basic race prep work?
 
#5 ·
Damn 352 lbs fueled up is light. Question is just how much you want to spend. Stock wheels are heavy as hell. Stock subframe is heavy as hell. Stock forks/triples are prob not too light. Stock battery is heavy as hell. Stock exhaust is obviously heavy as hell. That's probably about 50lbs right there. Fairings/stock seat probably adds another 10 or so. Yea I guess 80lbs is reasonable.

Would be cool if someone made a light aluminum frame for our motors. Surprised thats a no go with all the racing people do on these bikes. Wouldn't be cheap at all though... would be better to get another bike.
 
#6 ·
Damn 352 lbs fueled up is light. Question is just how much you want to spend. Stock wheels are heavy as hell. Stock subframe is heavy as hell. Stock forks/triples are prob not too light. Stock battery is heavy as hell. Stock exhaust is obviously heavy as hell. That's probably about 50lbs right there. Fairings/stock seat probably adds another 10 or so. Yea I guess 80lbs is reasonable.

Would be cool if someone made a light aluminum frame for our motors. Surprised thats a no go with all the racing people do on these bikes. Wouldn't be cheap at all though... would be better to get another bike.
Yeah, most of this stuff is doable in my shop. I will keep the stock wheels, unless a fairly decent set shows up on ebay. I have already swapped the forks for R6 forks, I do plan on building a new alum subframe with a carbon fiber battery and electronics tray, the battery is already swapped out to a 12 cell Ballistic (I had that on hand, otherwise I would have used an Antigravity battery), Sold the heavy SS Yosh exhaust and will use a carbon unit (unsure of what brand to get?), and fairings will be race fairings of course. I do have a build sheet started on my blog, but for the first year it will be kind of mild for a build. I guess only time will tell if this gets done or not.
 
#7 ·
Well I managed to get a start on the subframe over holiday break. It is about complete, other than some mounting tabs for the new CF battery tray I will be fabricating. The new tail section from moto forza looks good, but it was a PITA to fit the wide stock subframe rails. Next up is exhaust and electronics. Funds are already saved for Race Tech suspension upgrades, but I don't want to do that until I know the final weight of the bike
 

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#8 ·
Well I managed to get a start on the subframe over holiday break. It is about complete, other than some mounting tabs for the new CF battery tray I will be fabricating. The new tail section from moto forza looks good, but it was a PITA to fit the wide stock subframe rails. Next up is exhaust and electronics. Funds are already saved for Race Tech suspension upgrades, but I don't want to do that until I know the final weight of the bike
Good stuff, I am sure that your Kawasaki Superleggera will rock!

Keep us informed :)
 
#9 ·
I was able to learn a few new things. One was how to make my own Carbon Fiber parts, and the other was about back purging stainless steel when welding (night and day difference when its back purged). Other than that, not a whole lot to update because it took me a while to iron out the details when learning these new processes.

 
#10 ·
I was able to learn a few new things. One was how to make my own Carbon Fiber parts, and the other was about back purging stainless steel when welding (night and day difference when its back purged). Other than that, not a whole lot to update because it took me a while to iron out the details when learning these new processes.
I was ready to say that, carbon fibre or not, a cover is still useless weight but then I realised exactly what you are moulding there :cool:
 
#20 ·
Engine is put back together from the collet came out of the valve spring retainer, and it worked great (exceeded my expectations)on the first full trackday in June.

Just put the video together, Video was shot about 3 months ago. I used all GoPro equipment to shoot it.

 
#21 ·
Good job and video!


I have great family motorcycle "tradition" and my hands are itching every time I watch nice videos like yours.


My grandma is more than a hundred years old and she has more broken bones than Mick Doohan :laugh:


Enjoy your bike as much as you can, you deserve it!
 
#26 ·
A couple weeks ago I crashed in corner 4 at BFR (lowside). I feel it was a combination of my own fault and bike setup. Besides being shook up I was ok, and I was able to get the bike back together and go back out on the track.

The following week 9/5/15 felt great and I had planned on riding all three days the 5th, 6th, and 7th. I somehow caught the flu and was unable to ride the 6th. The 7th I made great progress though. I was able to improve my drive out of corners, increase my corner speed, and my overall lap times have dropped significantly from the start of the season.

I did a slight change to the ride height in the rear of the bike. I did 2 full revolutions OUT on the shock clevis which resulted in a 4mm raise in ride height in the rear. I also did a couple dampening changes while at the track. The bike would fall into corners much easier and I felt I could hold a line better without the bike wandering halfway through the turn.

All in all I have one more trackday left on the 30th. I feel this bike and myself have made great strides in progress over the season. I do have to admit, I mis my R6r, but I like this bike much better, it could be all the work that I have driven into it and I need to remember, it is what it is.

 
#28 ·
you might find some helpful info in these videos
BlackDog, thank you for the heads up. Every trackday is a day I try to rid myself of a bad habit. Ride Smart has some of the better videos explaining riding positions and other riding techniques. I will be the first to admit, I have alot more to learn, but I also have to be appreciative of what I have accomplished so far this year.
 
#29 ·
Every time you walk away safe is an accomplishment IMO, even better when you do it with a smile. Improvement will come with training and experience...but always keep safety first.

Ty is a pretty solid racer and has great advise...
track records

and of course Dunlop Racing Tires and Racetech Suspension is where its at. :Burnout:

I think we had raised the 09zx6r almost 1.5" overall to help the cornering
 
#30 ·
and of course Dunlop Racing Tires and Racetech Suspension is where its at. :Burnout:

I think we had raised the 09zx6r almost 1.5" overall to help the cornering
Racetech is who I went through for my fork work and gold valves, and Dunlop Q3s are the tires I am currently running. Although I am not running to the edge of the tires, I feel I have met the limit of what the tire can do for me. Going to a race compound might be more expensive it will save me in the long run and give me some added confidence in the corners.

Most guys at the track are either on Pirelli or Michelin.
 
#32 ·
My last track day I about dropped a valve again. I blame this to downshifting into a gear that it was not ready for and over reving the bike in the process. (operator error) I decided to try and alleviate this problem by using Kibblewhites Heavy Duty valve springs, installing a slipper clutch, and few other odds and ends.





 
#33 ·
Nice upgrades :smile2:


Tell us what you think after trying them!


My opinion is that gear shifting even when going for faster lap times should be clean instead of fast. I mostly blamed the long throttle travel for that, especially when up shifting down the straights, and planned to do the short/quick throttle zip line mod.


Anyway, good luck with new components, I am sure you 'll see great improvement.
 
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