RS Warrior Forum banner

1 - 20 of 375 Posts

·
Registered
Joined
·
229 Posts
Discussion Starter #1 (Edited)
Two weeks ago I had a chance to buy a 2004 Warrior as a project bike.
It is in great condition and came with a lot of goodies that I'm in the process of selling.

This is what it looked like 2 weeks ago:



To visualize what I hope to accomplish, I took a warrior stock image and painted the changes in Photoshop. My Photoshop skills are lacking and the resulting image is somewhat crude, but it was good enough to convince me to buy a used warrior and go after it.

Here is what I hope to end up with next spring:

 

·
Registered
Joined
·
229 Posts
Discussion Starter #2 (Edited)
The first goal was to possibly improve handling by changing some of the geometry without changing the existing frame.

By shortening the rear suspension (dog bones) the swing arm axle was raised by 1.5". This increased the swing arm angle from 6.5 degrees to 11 degrees.
This also changed the angle of the forks by 1 degree from 60 to 61.

Here are some pics to show the difference:




I also got a new tire, different in size. Instead of a 200/50 I got a 200/55 mounted on my rear rim. It's cross section is rounder then the stock size and should hopefully also increase handling in and out of turns.

 

·
Registered
Joined
·
229 Posts
Discussion Starter #3 (Edited)
The next step was to change the riding position.
To me it felt like I was sitting to much "on" the bike. I'd like to sit more "in" the bike and feel more "of" the bike as a result while riding.
This will affect handle bars, seat, and foot controls.

I found a good looking clubman bar and used risers from a Roadstar to replace the drag bars.




I'm planning on using the stock bar controls and switch housings.
 

·
Registered
Joined
·
229 Posts
Discussion Starter #4 (Edited)
The change from forward controls to rear sets posts an interesting challenge.

To get the whole layout process started, we drilled and tapped holes above and below the swing arm axle.

This allowed us to fasten 2 pieces of 1/2" MDF to the frame in the area the rear sets would be located.


I sat on the bike, held up my legs where I felt it to be right, and my buddy Glenn traced my boot and heel on each side to locate the foot pegs.
Glenn had a used R1 rear set to clamp on the boards just to get a visual.
Left side shifter bracket:


Right side brake bracket:




I just got the new rear sets in and will post pictures as soon as I get them.

It's gonna be a lot of fun to mock up the new ones and to make them fit.
 

·
Premium Member
Joined
·
3,936 Posts

·
Banned
Joined
·
5,508 Posts
that seat location and clip on bars will definately be laying you down on the bike , not cafe style more like top fuel style. unless yourr 6 foot 6 or better. btk572
 

·
Registered
Joined
·
229 Posts
Discussion Starter #9 (Edited)
I picked up the new R1 rear sets yesterday.
Nicely milled, with a lot of adjustability, off of ebay.

Right side brake setup

Left side shift setup

It took me all of last night to figure out which parts needed to be replaced to make them work on my bike. The layout plates with the mounting holes came in handy.
Here are the parts that need to be fabricated to make it work.

I get the cad file to a metal shop and have the parts water jetted from 1/2" and 1/4" aluminum.
 

·
Registered
Joined
·
229 Posts
Discussion Starter #10 (Edited)
Yesterday we got the swing arm out, cut all the tabs for the belt guards off, and cleaned it up for powder coating



Last Saturday, as I was taking various covers off the engine for powder coating, I wanted to change the look of the pulley cover and expose the pulley. I have seen it done here on several bikes and like the look.

Glenn set up his rotary table on the mill and cut the opening.
First we had to set it up and clamp it down to hold it.


After we had it secured, Glenn did his magic!


To keep it from moving, we ran multiple passes.


Glenn at work!

And the finished piece on the bike!


Ready for powder coating in black.

Its' coming together.

Thoughts and comments are always welcome! ;)
 

·
Premium Member
Joined
·
3,936 Posts
I still see no pictures...

Rob, do you see the 2 pics below? they are the only 2 pics on this thread. I would love it if wolf raider would post step by step pics of his build.




 

·
Vendor
Joined
·
7,301 Posts
Based on his comments it seemed like he was trying to write a caption to go along with a pic...I pasted the code behind the scenes without the tags.
see below

he is pasting in pics he loaded into his album but his album is empty as well... dunno

Two weeks ago I had a chance to buy a 2004 Warrior as a project bike.
It is in great condition and came with a lot of goodies that I'm in the process of selling.

This is what it looked like 2 weeks ago:

http: //www.rswarrior. com/forums/members/50561-albums6625-picture29641.jpg[/IMG]
http: //www.rswarrior. com/forums/members/50561-albums6625-picture29649.jpg[/IMG]
To visualize what I hope to accomplish, I took a warrior stock image and painted the changes in Photoshop. My Photoshop skills are lacking and the resulting image is somewhat crude, but it was good enough to convince me to buy a used warrior and go after it.

Here is what I hope to end up with next spring:

http: //www.rswarrior.com/forums/members/50561-albums6625-picture29633.jpg[/IMG]


The first goal was to possibly improve handling by changing some of the geometry without changing the existing frame.

By shortening the rear suspension (dog bones) the swing arm axle was raised by 1.5". This increased the swing arm angle from 6.5 degrees to 11 degrees.
This also changed the angle of the forks by 1 degree from 60 to 61.

Here are some pics to show the difference:

http: //www.rswarrior .com/forums/members/50561-albums6625-picture29665.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29657.jpg[/IMG]

I also got a new tire, different in size. Instead of a 200/50 I got a 200/55 mounted on my rear rim. It's cross section is rounder then the stock size and should hopefully also increase handling in and out of turns.

http: //www.rswarrior .com/forums/members/50561-albums6625-picture29729.jpg[/IMG]


The change from forward controls to rear sets posts an interesting challenge.

To get the whole layout process started, we drilled and tapped holes above and below the swing arm axle.
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29697.jpg[/IMG]
This allowed us to fasten 2 pieces of 1/2" MDF to the frame in the area the rear sets would be located.
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29705.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29713.jpg[/IMG]
I sat on the bike, held up my legs where I felt it to be right, and my buddy Glenn traced my boot and heel on each side to locate the foot pegs.
Glenn had a used R1 rear set to clamp on the boards just to get a visual.
Left side shifter bracket:
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29769.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29737.jpg[/IMG]
Right side brake bracket:
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29761.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29753.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29745.jpg[/IMG]

I just got the new rear sets in and will post pictures as soon as I get them.

It's gonna be a lot of fun to mock up the new ones and to make them fit.
I picked up the new R1 rear sets yesterday.
Nicely milled, with a lot of adjustability, off of ebay.

Right side brake setup
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29969.jpg[/IMG]
Left side shift setup
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29977.jpg[/IMG]

It took me all of last night to figure out which parts needed to be replaced to make them work on my bike. The layout plates with the mounting holes came in handy.

Here are the parts that need to be fabricated to make it work.
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29985.jpg[/IMG]

I get the cad file to a metal shop and have the parts water jetted from 1/2" and 1/4" aluminum.
Yesterday we got the swing arm out, cut all the tabs for the belt guards off, and cleaned it up for powder coating

http: //www.rswarrior .com/forums/members/50561-albums6625-picture29793.jpg[/IMG]

Last Saturday, as I was taking various covers off the engine for powder coating, I wanted to change the look of the pulley cover and expose the pulley. I have seen it done here on several bikes and like the look.

Glenn set up his rotary table on the mill and cut the opening.
First we had to set it up and clamp it down to hold it.
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29809.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29801.jpg[/IMG]
After we had it secured, Glenn did his magic!
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29817.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29825.jpg[/IMG]
To keep it from moving, we ran multiple passes.
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29841.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29865.jpg[/IMG]
Glenn at work!
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29857.jpg[/IMG]
And the finished piece on the bike!
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29873.jpg[/IMG]
http: //www.rswarrior .com/forums/members/50561-albums6625-picture29849.jpg[/IMG]
Ready for powder coating in black.

Its' coming together.

Thoughts and comments are always welcome! ;)
 

·
Registered
Joined
·
229 Posts
Discussion Starter #16
Today it was time to clean up the frame and get rid of the tabs holding brake reservoir and exhaust.


All cut off, ground and sanded down, and painted.



Like it a lot! Just waiting for the swing arm and covers to come back from powder coating.
 

·
Registered
Joined
·
1,980 Posts
Coming along really nicely... I'm excited to see what you end up with. Whether you did it on purpose or not, your concept sure looks a lot like an MT-01 :)
 

·
Premium Member
Joined
·
3,936 Posts

·
Registered
Joined
·
229 Posts
Discussion Starter #19
Coming along really nicely... I'm excited to see what you end up with. Whether you did it on purpose or not, your concept sure looks a lot like an MT-01 :)
When I started out, I didn't know that the MT-01 existed. Never saw it before.
I don't like the lines on that bike. Just my 2 cents. :)
 

·
Registered
Joined
·
229 Posts
Discussion Starter #20 (Edited)
Today I was able to pick up the parts from powder coating and they turned out great.
I've used this company on my Raider build and they do excellent work.

Here is the swing arm, all lubed up, with new bearings, installed.



I also replaced the STAR billet chrome drive cover with a stock cover. This made a huge difference on the right side. At the same time I had the little cam cover powder coated also to achieve a more blacked out look on the engine.



On the left side I had all the chromed billet covers also powder coated in addition to the pulley cover, which we milled out last week.
I'm very happy with the results!



Now its just side stand and oil lines that need the same treatment. But first I need to fabricate a block from aluminum, to mount under the side stand, so the bike does not lean too much when sitting on it.
 
1 - 20 of 375 Posts
Top