VULGR's race build - Yamaha R3 Forum
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post #1 of 93 Old 03-16-2016, 05:14 AM Thread Starter
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VULGR's race build

It's finally getting to that time of the year when racing starts. Last year I entered my first race/s on a ninja 300 with some mild success locally. This year Yamaha announced an R3 cup to run along side the Australian Superbike (ASBK) series, Yamaha are offering a brand new R6 for the championship winner and I couldn't resist giving it a shot
I'm from Western Australia, ~3000km away from all of the race rounds, so I'll be flying back and forth to compete. I flew in to Sydney on Saturday and went to have a look at a couple of vans that I could use to transport the bike around the east coast of Australia. I ended up negotiating a deal on an old ford transit van and drove to the Yamaha dealership


I had already organised the race package supplied by Yamaha Australia before I flew out. The package includes:
-a brand new 2016 Yamaha R3 (I chose matte grey)
-Fairing kit
-Akrapovic full racing exhaust system with Ti muffler
-Racing rear sets with multiple adjustments
-Handlebar lowering kit
-Gearing set
-MUPO Suspension kit – complete rear shock absorber and Front fork kit
-Graphics kit
-R+G kit including crash knobs, engine case covers, rear stand pickups, chain guard, radiator protector, muffler mounting bracket
-AIS pollution system block off plate
-4 litres of synthetic engine oil and engine oil filter
-Oxford rear race stand
-CD with parts book, service manual, kit fitment manual, etc.

Only half of the parts had been sent out before Saturday (1st race is next weekend) so they've really left things until the last minute, I'm really not impressed with How Yamaha have organised this race series, the preparation is something you would expect out of a back yard and they don't seem to know the answers to any of the questions I have. Most of the R&G items arrived (not the engine cases though), akrapovic exhaust, "handlebar lowing kit" (an aluminum spacer an m6 bolt), block off plate, MUPO rear shock and fork kit, different sprockets and "graphics kit" (a couple of stickers with series sponsors, but no fairing kit to put them on). I also purchased a new set of Pirelli supercorsa's (I expected them to be installed before I arrived but they weren't), new brake pads (also haven't arrived yet) and a ramp to load the bike in the van. Since the rear paddock stand hadn't been shipped yet I was forced to buy another rear stand that will be obsolete when they actually send out the parts they agreed to supply!
Anyway, I picked the bike and parts up from a dealership in Sydney that I had organised previously and headed to Newcastle (2hrs north of Sydney) to my sisters house where I would prep the bike.



The first trackday was organised for Tuesday 15th, I would need to leave Monday afternoon though which meant I had half a day Saturday, a full day Sunday and half a day Monday to prep the bike. I had been in contact with Yamaha and they had assured me the rest of the parts had now been sent and I was expecting them Monday morning.
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post #2 of 93 Old 03-16-2016, 05:39 AM Thread Starter
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I arrived in Newcastle at about 3pm Saturday afternoon (the following all happened over the following 45hrs) and began stripping all of the fairings off the bike

I installed the block off plate, removed the stock exhaust and replaced it with the sexy looking akrapovic full system. As usual, a lot of weight savings from swapping to a full system


Next was the suspension, I laid the bike on its side (on the grass) and removed the rear shock and replaced it with the great looking MUPO kit provided




I then swapped out the stock front fork internals for the aftermarket MUPO kit and re-installed the forks (still look stock from the outside)


I changed the front sprocket -1 as I had spoken with @Aufitt who had told me it is geared a little long for our local track and the track I would be racing on looked like it'ld be roughly the same speeds at the end of the straights.

I didn't need to ride with the ABS to know it'ld be too restrictive and interfere with racing so I replaced it with a HEL SS braided front brake line and bypassed the ABS. I disconnected the rear brake from the ABS unit as well and connected the stock line directly to the master cylinder. New fresh dot 4 brake fluid was also used when bleeding the new system


I drilled and lockwired all of the necessary caps and bolts and relocated the bars below the top triple tree.
It was Sunday afternoon by the time I had gotten the bike to this point and there wasn't much more I could do until the remainder of the parts arrived on Monday morning so I spent some time catching up with the family
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post #3 of 93 Old 03-16-2016, 05:54 AM Thread Starter
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Monday morning had arrived and I was waiting an onslaught of parts and accessories to arrive.
A couple of parts were due to arrive from my sponsor www.kaneg.com.au
I was waiting for a head lift front stand and trailer mate to make transporting the bike a million times easier! The shipping company actually tried delivering these Thursday but I hadn't yet arrived and rescheduled the delivery for Monday.
I was also waiting on the second half of the the parts supplied by Yamaha, most importantly:
-fairings
-engine cases
-rearsets


While I was waiting I began setting up the van for the trip (400km away) to the track that afternoon




I waited until 1:30pm and nothing had arrived, I'ld need to put the street fairings back on and use them for the track day
I left the belly pan and most of the black plastics off and loaded the bike up

A little bit of duct tape to hold it together since o only installed half of the fairings


I drove down to Goulburn, 15mins away from the racetrack (Wakefield Park) and stayed the night there. I was looking forward to an early start at a track I knew very little about
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post #4 of 93 Old 03-16-2016, 07:41 AM
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For a West Aussie rider to be doing what you are embarking on is monumental!




(USA folk this is the equivalent to racing in New York when you are from California... AND building the bike from the back of the van on the way.)
Best wishes and following with interest, you can do this

I blame the Internet.
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post #5 of 93 Old 03-16-2016, 10:56 AM
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awesome! takes a ton of passion to be doing what you are!
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post #6 of 93 Old 03-16-2016, 03:42 PM
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The trials and tribulations of club racing - I love this thread already.

Either you or @Aufitt selling team shirts to offset expenses? PM me the particulars if you are - would love to help out if you need it.
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post #7 of 93 Old 03-16-2016, 04:42 PM
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I like your method of removing the rear shock lol. Never thought of that. What are your fork internals? I mean I get they are Mupo as you mentioned, but I have never heard of them. Do they work like an Intiminator or GVE? Almost look like Ricor Intiminators, but those have a different nut at the end.
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post #8 of 93 Old 03-16-2016, 06:05 PM Thread Starter
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Quote:
Originally Posted by Stirz View Post
The trials and tribulations of club racing - I love this thread already.

Either you or @Aufitt selling team shirts to offset expenses? PM me the particulars if you are - would love to help out if you need it.

Nah, not selling any merchandise, my major sponsor www.brandsense.com.au has been extremely supportive and generous though All they do is sell/make merchandise so I do get a lot thrown at me (hats, shirts, stubby holders, bottle openers, stationary, power banks and almost anything else I could want or use)

Quote:
Originally Posted by Kojiiro View Post
I like your method of removing the rear shock lol. Never thought of that. What are your fork internals? I mean I get they are Mupo as you mentioned, but I have never heard of them. Do they work like an Intiminator or GVE? Almost look like Ricor Intiminators, but those have a different nut at the end.

I hadn't heard of MUPO either but they were supplied with the race kit. The fork internals include a shim stack (from what I understand it's the same thing as an intiminator), linear race springs (the company supplying the spring couldn't tell me what spring rate or weight it is appropriate for though and unfortunately most of the paperwork and instructions were in Italian) and a taller spacer.


I'll update this thread on my track day this afternoon/tonight when I have a bit of time
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post #9 of 93 Old 03-16-2016, 06:12 PM
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awesome! keep us updated
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post #10 of 93 Old 03-16-2016, 09:37 PM Thread Starter
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I woke up nice and early Tuesday morning, had a cup of coffee and headed to the track. Wakefield Park has great spectator areas where the whole track is visible, the surface looks great and visibility through the corners looks like it will be great
I unloaded the bike and all of my gear and proceeded to sign on for the day. At this point my bike still hadn't travelled a single km


Unfortunately due to the shipping company I still did not have my front stand so I'ld need to run my front tire without a warmer. I was surprised at the lack of scrutineering involved at the track day, they only had a really quick look at the bike just before I left pit lane


I was keeping in mind that I had never been to this track and wasn't familiar with the layout of the circuit, I was also aware that my front tire was stone cold so I wasn't about to go out and push at 100% for the first session
The corner visibility was amazing, you could see how sharp the corners were and your apex and exit before you even arrived at the corner, this instilled a lot of confidence within the first few corners. I was just cruising at about 50% pace, not aggressive with the throttle or brakes and not leaning the bike very far at all. I got to the tightest left hander (turn 8), I had done 90% of my braking before arriving at the corner and was still at a very slow pace, I trail braked ever so slightly as I began to tip in... The front slid and before I had time to react the bike was sliding down the track
Scratched the front upper fairing and left fairing, cracked the left tail fairing, snapped mounting point for the swing arm spools and bent the gear shifter. The bike had less than 2km and looked like a mess! It was a really slow crash and I hoped up without even the slightest soreness or injury




A bit of duct tape and I was ready to head back out for the next session. This time I decided I would place the warmers over the top of the front tire, it wouldn't be perfect but it would get more heat into the carcass and surface of the tire than nothing. I went out for the second session, took it even easier for the first couple of laps before slowly upping the pace (still WAY off race pace). The front and rear tires were sliding everywhere! These tires are possibly the worst tires I have ever ridden on. I made it through the session and pulled in to the pits. I'ld need to change over to the supercorsa's I had brought with me, unfortunately there wasn't a tire changer at the track and I'ld need to head in to town.
There was one more session before lunch so I made the decision to stick with these and drive into town on the lunch break. I started pushing a bit more in some of the faster corners but remained careful on the tighter stuff, I started getting some great pace through these faster sections. About 16mins into the session I was flying down the front straight, full throttle through T1, I had just gotten off the throttle and began to load the front suspension. I was barely leaned over (maybe 10% lean angle) and the front end washed away. I hadn't wiped off any speed at all and this was the fastest part of the track, looking at the data from the previous laps it was a 160km/hr (100mph) corner. As I slid and tumbled along the Tarmac and grassed areas I watched the bike explode into thousands of pieces (a slight exaggeration). I jumped up and moved out of the way as quickly as possible to safety. I had smacked my head, slid for 50m and tumbled a few times, surprisingly I had no soreness or pain anywhere. The bike was destroyed though!
Completely smashed every fairing piece that was on the bike, the headlight was smashed, tail light smashed, right rearset shattered, right handlebar snapped, left handlebar bent, wiring in the right switch block cut, ignition snapped, both seats damaged, engine cases scratched, radiator hoses disconnected, slight damage to the radiator (not leaking), damaged rear line and reservoir, small dent in the swingarm, scratched and dented exhaust and a few other small bits and pieces
(Note this is what was left, I hadn't removed anything at this point)





10 days to have it ready for the race weekend
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