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01 to 06 conversion discoveries.

62K views 254 replies 57 participants last post by  Mateus  
#1 · (Edited)
My 01 ate its own gearbox last December, and has been parked ever since. I finally pulled my finger, and the engine out, and I plan to get her going by this December. I've also modified the living shit out of my 06 over the years, and I have a large pile of low km leftovers gathering dust....

So I pulled the motor, and while I contemplated the complicated job of rebuilding the gearbox, I decided to distract myself by trying a few exchanges...

If you're interested, here's what I've discovered so far:

The steering stems on the 01 and 06 are the same. This means the bearings and races are the same, so the 06 triple clamps go onto the 01.

The ignition barrel mount ponts are the same, so the 01 ignition barrel goes into the 06 top clamp. Although there is about an 8mm space between the barrel and the ring around it, the steering lock still works. Asthetics will come later.

Obviously, the 06 forks, wheel, axle, calipers, braided lines, master cylinder, resevoir & clutch perch, go into the 06 triples. As will the leftover Graves clipons, Braking wave disks, CRG levers and brembo clear resevoir hose, I've got kicking around!

They still mate up to the 01 switchgear, but I'll need an 06 resevoir mount and mudguard (I have a spare thanks to a disk lock incident). The 06 forks are 25mm shorter than the 01 forks, and they also have at least 20mm less offset. So the front end will be considerably more loaded than before. WOOHOO!

Lucky the unknown aftermarket damper from the 01, will fit to the leftover Graves clamp from the 06 then.

In the middle... the 01 and 06 footpeg hanger mounts are the same. As are the footpeg positions, and the shift link pivot point, relative to the lever pivot point. This means my spare Graves rearsets will bolt straight on. Whether the brake resevoir and shift likage fit, is another matter.
I'm not sure of the difference between the shift shaft positions, on the engines yet, so I'll let you know, when I try.

At the rear...

The 06 shock absorber is the same length, and the mounts the same width, as the 01. I haven't tried yet, but it should bolt straight in.

The 06 rear axel is the same diameter as the 01, but 15mm shorter. So the 06 rear wheel will fit in, but will need spacing out to fill the wider spaced 01 swingarm. My leftover Braking wave rear disk will come in handy here too!

The 06 rear caliper and mount fit in, but do not lock to the swingarm, and would need a block welded on, to do so. The 06 caliper mounts to the hanger differently than the 01 caliper, so they're not interchangeable. This would leave me with gold spot front calipers, and blue spot rears, which is obviously unacceptable!

Also the 06 mirrors and indicators look like they'll fit but, unfortunately, the slightly crap carbon 06 tail I have leftover, won't fit on the 01. So I wont be building an 01 replica of my 06....Oh well!

Anyway, it's midnight here, and I want to grab a small amount of winter sunshine, to thrash the 06 tomorrow, so I'll let you know as I find out more....
 
#4 ·
Been there, done that! :thumbup

I'm still waiting for someone to shoehorn a 04-06 motor into an earlier bike.

If you are bored and have the swingarm out try the 04-06 swingarm in the early bike. Been a few around wanting to know about that....
 
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#10 ·
Ding ding...round two...

Today I continued with the easy stuff, 'cause it's easy. I put the front end together, and found out a couple more new things.

The 01 and 06 clutch switch (that attaches to the clutch perch) are the same.

The 06 wheels are 5.9kg lighter than the 01 wheels, the pair. This includes disks, cush drives, sprockets, and tyres.

The 06 front disks are 200 gms lighter than the 01 disks, despite being 22mm larger in diameter.

I've lost the oem brake banjo bolts, there's probably going to be a bit of a list of miscellaneous parts, by the time I'm done.

Here are a few pics of my bits...:sneaky

The cause of the project,don't mention the F word!
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Suspension
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Wheels
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Brakes
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Bars, levers & axles
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06 & 01 footpegs
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Mirrors and indicators, well...why not eh?
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The point of this exercise is mostly to make use of the 06 gear I've got sitting around. I intend to spend the absolute minimum I can, on the chassis. The gearbox will cost what it costs, so be it. But if a 2nd hand full system should turn up...well that's another story.
 
#24 ·
The 06 wheels are 5.9kg lighter than the 01 wheels, the pair. This includes disks, cush drives, sprockets, and tyres..
Wow... That's 13lbs for us on this side of the pound. Figuring that the 02-03 wheels are almost exactly the same as 00-01 wheels.

Add the loss I got from the 320mm rotors and the fact I have Dynamags for the 04-06 and that be a lot of savings. :sneaky

(Now if I could only figure out what's wrong with the forums so I can read all the threads again! :crash )
 
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#12 ·
And here are a few more shots of the progress...

Yokes, forks, and clamps on, one upsidedown!
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Bars and levers on
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01 clutch switch on 06 perch
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01 ignition barrel in 06 top yoke, fits like a cock in a shirt sleeve!
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06 Front wheel, brakes, & mudguard, but no banjo bolts for the braids yet.
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#16 ·
01 ignition barrel in 06 top yoke, fits like a cock in a shirt sleeve!
:hammer: :hammer:


Looking good mate, wish I had that much wrenching space. She'll be a wheelie machine with the diet you're putting her on. I never thought there would be that much weight saving from 01 to 06 wheels :scared
 
#15 · (Edited)
My next project will have an 01 front and rear end on it !:hammer:

PS: I forgot to mention.....

The ignition barrel is sitting 5-10mm too low, for the locking pin to work. So I'll be removing the top yoke, and trimming the two mount points for the barrel, until the lock works as it should.
 
#17 ·
I know! that's more than I lost when I put the BSTs on the 06. People like Blu and Marcaztls who put BSTs on their 98 - 03 R1s, must of felt a hell of a difference! There must be more than 8 kg in it.
 
#19 · (Edited)
More questions than answers today...

06 shock in 01 frame, the only difference between them is the resevoir...
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Which only has 27mm of clearance before it hits the swingarm, and that's with absolutely no weight on it.
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So that wont work, unfortunately.


06 rearsets (Graves) on 01 frame, the shift rod passes through the frame, but without the engine in, I don't know whether it will meet with the shift arm.
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01 rear master cylinder on 06 rearsets, using the 01 bolts. The joint fits on the lever fine, using the 01 pin.
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Trouble...well it had to come eventually! The 01 caliper hanger would need so much removing from it, it wouldn't be strong enough. The 06 bracket needs 8mm more added to it, to fill the wider spaced 01 swingarm.
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The upper inside of the arm protrudes further than the lower edge. The upper edge of the 06 hanger is supported, but not the lower. I think this would put too much stress on the upper surfaces.
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So my best idea so far, would be to weld another 01 axle adjuster block to the 06 hanger. Then machine it down to the correct thickness, along with the surplus material above the rear caliper mount hole.
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If anyone has previous experience with this, or another idea...sing out.


At least I wasn't too lonely in the shed....
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If I got bored, I could always fit the new clutch and fork seals on my mates TLR.:crash
 
#20 · (Edited)
this is F*** good stuff woooh!!
i been saving a saving for a 04R1 Ohlins R&T front forks for awhile. So i can swap with my sh!ty 01R1 front end. I just love so much the radial braking system look.
great stuff Mr.!



p.s
do you think its possible to fit a 04-06 braced swingarm on a 01R1, just the way it looks on 04R1?
 
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#22 ·
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:corn
 
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#23 ·
is it just me or does anyone else find it strange how little has changed between the 01 and 06? i guess if it isnt broken dont fix it...
 
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#28 ·
There were very few changes, mostly cosmetic and EFI, between the 03 and the original 98. So the compatability goes all that way. Then there are a few components that go through to 08, and apparently the wheels remain the same today as in 04! Shows you how right they were. If only they could combine a stomping bottom end, with a bulging midrange, and a warp factor top end....surely it's not too much to ask!:hammer:
 
#30 ·
I left mine be... The 02-03 came with a dual piston and I was happy with it. I did want to flip it down like the older bikes, thought that looked good but never dot around to it.
 
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#31 ·
Big fan of the look of the radials and 5 spokes on the older R1s. Once the 04/05s started becoming parted out I jumped on the hybrid-R1 bandwagon.

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#32 ·
Awesome!! what did you do...? Take the forks of the 04R1 and moded into your 02-03R1?
looking :epimp...:fact
 
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#33 ·
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Photobucket lost half my picture album but here's my 2000, I have a 02-03 rear brake caliper and hanger thats been on since 2006. I always wanted to upgrade to a smaller aftermarket caliper & hanger but I never use the rear brake and those rear brembo calipers are not cheap. Looking forward to see how your bike turns out.
 
#41 ·
:bow
It was your awesome bike that inspired me in the first place. Brilliant job man, I love it. Mine will be low budget, but improved (hopefully). And I wont have to hold back at the track, unlike my 06, which owes me 7 + times as much $.
 
#35 ·
I am really interested in putting a newer swingarm (04+) and shock on an early R1. I hope you find a way!

Mine, 2000 R1:

Back in '07 I swapped in 07 triples, forks, clip ons, calipers and rotors and 06 wheels. It is true the wheels haven't changed since 04. Swingarm, shock, rear caliper and mount all 03.

The "rebuild" completely transformed my bike....rides smoother, easier to lean and brakes on a dime!

I would take an updated 00/01 over a new R1 anyday. :yesnod
 

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