Last year for my birthday I bought a 94 900rr with 20k miles on it for about $1800. I bought itr as a project bike and have since rerouted the wires. My next task is the tail as I think that is very bulky and ugly. I found a complete 2001 929 tail and bought it for $100 (good deal?). After taking all of my plastic off and stripping the subframe down I found that the very end of the tail is just a bit to fat maybe by an inch.

Has anyone done a mod to their subframe to fit a newer tail? Can I just cut off the rear cross bars, bend the subframe in 1/2 inch on both sides then reweld the bars back on?

I could also pick upthe subframe from the 2001 for $50 and attempt to weld the two subframes together.

Any thoughts, suggestions, or experiences are welcome.

 

I did a tail swap with a GSXR tail and had a similar problem. I grinded off about an inch of the end of the subframe, then angled the sides of the tubes to get the extra clearance.

Here's link to the swap how to I did.

http://www.rrzone.com/forums/showthr...272&page=3

It may give you some ideas.

 

When you say angled the sides of the tubes, do you mean that you bent the rear part of the subframe in after cutting off an inch or 2?

 

Nope no bending. Of course it depends on the tail and how skinny it needs to be. I cut off the tubing so it was flush with the rear bracket. Then grinded off the tubing at a 45 degree angle from where the welded in screw boss is on the outside of the sub frame tubing.

By grinding off the outer edges it allowed the tail where it curves in at the rear to fit right.

[IMG]local://upfiles/6897/BAA1C8C33F8948ABA50C89D4469AD8DF.jpg[/IMG]

 

I can see that you ground the top and bottom tubes. Did you cut bot of them as well?

I believe that my rear bracket is flush or very close to flush with the upper tubes? I believe that my subframe is a 94, is that what your was?

 

Yep, mine is a 94 as well. I cut the top off flush. I cut the bottom off right where it is welded to the top tube. Then used an angle grinder to grind the 45 degree angle until I almost came in contact with the screww boss on the outside. It a 45 degree angle on the side as well as the bottom. I went as far as I dared while still being able to use that screw boss. The angle is actually much more than 45 degrees.

 

OK I see what you are talking about. Now I have a few more questions.

What is the best way to inexpensivley heat plastic to bend it a bit? Hairdryer?

I might not need to heat the plastic but the reason I ask is because the two plates mounted on the sides of the subframe, about half way up(the black thing with fins mounts to the one on the right, I forget its name). I know that they are in ther way so I think that I will relocate them to the inside of the subframe. This might save me from haveing to bend plastic. Also I think that I will have to angle the tubes in the back and take off as much as I can because I just need a bit more clearance.

As for the main bolt holes on the 2001 cowling. I think that they don't line up the way the 94 cowlings do. Did yours? (I know that you used a GSXR) So maybe I will have do some additional welding........ I am not sure yet though. One step ata time.

 

I will also begin to post pictures. I have completely stripped the bike down and have some of it built back up again. I am thinking that this project might take me longer than initially expected. Oh well, more fun.

Does anyone know I good guide on how to reade wiring diagrams? So far I have been able to figure out where the front, back and sides are. Only because the diagram tells me. I would like to reroute the wires from scratch, but if it is to big of a pain then I won't. Or should I have my local shop do it?

 

A hair dryer probably won't be hot enough, you'll likely need a heat gun. Be careful it will also screw up the paint if your not real careful. The black thing is the rectifier/regulator. I didn't have to remove the plates, but I did weld an additional plate on the insode to mount the regulator to so it wouldn't be in the way of the tail.

The mounting points definately didn't match up. I cut off the ones in the front and made new ones. I also cut off and repositioned the front bracket that the rear seat/solo cowl mounts to. I was able to reuse the rear bracket by just drilling and tapping new holess in the right spot.

 

I think that I might have to move my front bracket as well, but I will wait to see until after I cut some of the subframe off and gring tonight. Wheich reminds me that I need to go buy an angle grinder and cutting wheel tonight.

Alright, I am at work and should probably be doing my job. I will post more later.