Footrest Plates & Footrests

[RC 166]

Okey, now I have mounted the tank and seat so I can try and evaluate the best possible position of the foot pegs. For this I am making some mock-up rearset plates with multiple peg positions to choose from. What do you think about the stance?

I also wanted to level the bike exactly as if it were complete and standing on the floor. I adjusted the front end with the help of a laser. Ohlins recommends certain sag targets and the result is that the front end sags 20mm more than the rear. It also helps to achieve a perfectly level design line to position the foot peg mounting holes on.

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[RC 166]

Finished my rearset mock-up plates and have also tried positions on them.
The adjusting range from OEM Sport Kit positions is 50mm back and 25 mm down in 25mm steps.

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I also compared my streetfighter bar against the Sport Kit bar ends and found that with my top yoke and bar clamps the new bar gets VERY close to OEM Sport Kit bar position, both height and backwards.


I choose foot peg position 50mm back, 25 down. Once this is decided, the rest is much easier. And I can use these mock-up plates for testing the brake/gearshift levers, rear master cylinder position etc....

[RC 166]

Sorry,

I should also have expressed the foot peg positions according to the requirements mentioned in the first post (dimensons A-D).

Here they are:

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[Jeff Bennetts]

Here are a few custom rearsets.

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[Jeff Bennetts]

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[RC 166]

Thanks Jeff,

Very good contribution to this thread's knowledge base! Lots of inspiration when building a custom.

[RC 166]

512tr,

"Whit a shorter brake levers/pedal the torque will be less on the pump, but that does not necessarily mean that the brakes will be bad.
Why not fabricate a bracket that allows for replacement to another pump if this setup gives weak braking power.
I use OEM plates, footrests and pedal with Brembo caliper, Kawasaki brake pump (5.5"x 17 rear rim)."

With this build I simply can not use the long OEM brake pedal. But I made some quick calcultions to show the difference in caliper piston forces when using a shorter pedal and 14mm vs 1/2" cylinders. CBX, ZX-9R, and GSX-R1100 all use 38mm caliper pistons and I use 100N as a given pedal force in all cases.

I intend to use the 14mm CBX master cylinder to start with as I think one could live with a little more force on the pedal to get the same result as the OEM setup.


All OEM CBX scenario

Rear Brake Force w. CBX MC & Pedalcropcrop2.jpg

Suzuki GSX-R1100 pedal and 14mm CBX master cylinder

Rear Brake Force CBX MC & Suzuki GSX-R1100 pedalcrop.jpg

Suzuki GSX-R1100 pedal and 1/2" master cylinder

Rear Brake Force w. Suzuki GSX-R1100 MC & Pedalcrop2.jpg

[Syscrush]

I'll say that I generally love an analytical approach and this kind of attention to detail, but unless you're gonna do a bunch of 2-up riding in the rain, who cares about the rear brake? I used to think that I relied on it to stabilize the bike in low-speed parking lot maneuvers, but then I found out that my rear caliper had been seized for a year and a half...

[RC 166]

Sorry, last example had a writing error at "Total Force Ratio",

Here is the corrected one...

Rear Brake Force w. Suzuki GSX-R1100 MC & Pedalcrop3.jpg

[RC 166]

Syscrush,
I have also been there, that's why I am not afraid to give away a tiny bit of ratio. I just wanted to show it's not a big difference anyway...

[512tr]

Impressive engineering!

Your swing arm transformation from mono shock to twin shock is genius, but the swing arm itself is maybe too wide, bulky and overkill for a twin shock. If you went for slimmer swing arm you’d have much more space to play with.

I'm just saying...with your creativity, engineering and fabrication skills you should have fabricated your own swing arm.

[Syscrush]

Syscrush,
I have also been there, that's why I am not afraid to give away a tiny bit of ratio. I just wanted to show it's not a big difference anyway...

OK, that makes sense. From reading your post I wasn't sure if you thought that the 40:1 vs 33:1 ratio was a big or small change.

Whatever route you go, I'm really looking forward to seeing the result.

[512tr]

You just disappeared, any updates please?

[RC 166]

Be patient, I have not dissapeared, just made some multitasking such as working for customers, building work at my summer place, upgrading all servo amplifiers and servo encoders on my 4-axis CNC milling machine AND made the new rearset footrest plates we discussed last time...

They are not complete yet. There will be piggyback plates for the pillion pegs so I can remove them at will. I need to make a new brake pedal that matches the master cylinder better and all other small hardware to go on the plates. I ended up making a small sandwich sub-plate for the ZX-9R master cylinder. On the left side I managed to use the CBX OEM gear shifter lever, it just needs a longer threaded adjusting rod.

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[bobcat]

When the shocks are compressed* have you accounted for clearance between the swingarm
and master cyl. where the brake line connects ? *Travel

I used the FZR swingarm on my CB900F and had to move the mast. cyl. way up.