GSXR Flywheel Mod

[Smev]

Well I have Mine all fitted and running sweet!!

I thought I'd do a small write up or 'how to' about it.

After my accident i found the engine casing to be cracked and immediately thought why not do the conversion I had read about on here. So after aquiring all the parts necessary (adaptor plate from G-Force Performance, flywheel and alternator/windings from a GSXR K7) I set to work.

With the fairings removed you will see the left hand engine casing which will also need to be removed.


once removed it should look like this

you can see the standard NC30 flywheel which covers all the windings - by doing this modification you are effectively reversing this and lightening it by using the lighter rotor, thus giving an improved response from the engine when whacking the throttle open!!

Next you need to remove the fly wheel centre nut. - this is easier said than done if you don't have the correct tools. A friend helped me with this using a holding tool to stop the flywheel turning as I undid the nut.
At this point you may need to use a flywheel puller to get the flywheel off the shaft - however - I left my bike overnight and returned to find that it had fallen off of its own accord!

This is the flywheel you will need to remove and set aside (hopefully) never to be used again!


you will now be faced with the windings which are held in place with 4 bolts -


Disconnect the windings/alternator from the loom by tracing the wires back to the right hand side of the engine.

You can now remove the 4 bolts holding it in place and again set it aside never to be used again!


This will leave your bike like this - all ready for reassembly.

[CMSMJ1]

good call mate. I have had a ballache getting mine to seal on ne gasket. no idea why - so I took it apart again yesterday and did it again.

Hope to get home and see no little oil spots on the garage floor..

It does work very well though. Not got a multimeter on it yet to test output but I am sure it works just fine...as my moto starts on the button.

[Smev]

Before re-assembling can go ahead a few things have to be done -

The sound proofing in the engine casing has to be removed - simply undo the bolt and gently lever it out


Next insert the adaptor into the casing and mark where the two lower holes need to be drilled.
Adaptor


Casing with holes drilled and fins removed using a dremmelto ensure good fitment of retaining bolts.


a small hole also needs to be drilled internally for the bracket that holds the wiring out of the way of the spinning flywheel.

Fit the adaptor to the casing and secure with the two bolts on the outside ofthe casing.
Next you need to fit your GSXR K7 windings to the adaptor bracket (unfortunately there are no pics from here on as I was so excited I forgot to take them!!)
It mounts to the 3 holes on the adaptor. Ensure the wires are routed so that when fitted they won't rub on the flywheel. - you can also use the VFR rubber grommet to stop any oil from blowing out through the gap for the wires.

Back to the bike side of things - fit the Flywheel onto the shaft so that it cups towards you - fit the washer and nut, and torque accordingly (again help maybe needed from a friend with the correct tools!)

You are now ready to refit the engine casing with adaptor etc.
Using a new gasket or sealent if you prefer, slowly offer up the casing to the bike ensuring that no wires are trapped/caught.
Refit the mounting bolts for the casing and tighten as required - be careful not to overtighten and crack the casing
The wiring from the windings/alternator can be connected up to the VFR loom using the connector from the GSXR by cutting off the locking part of the Suzuki connector. they should slot together nicely.

And that is just about it!! time to fire her up and see the quicker pick-up!!


(disclaimer - this is all done from memory and all people should take it on themselves to ensure the bike is safe and roadwrthy before riding)

Hope some people find this useful

Cheers Smev

[SilverSurfer]

hi I`m struggling to get the flywheel off ,the 14mm bolt is already out but it still doesn`t move

[royster81]

you need a flywheel puller.

[JC120]

Yep you need the puller. It was only $11 on ebay shipped. I just got my flywheel off. Good God the stock one is heavy compared to the 2008 gsxr1000 one.

[Neosophist]

hi I`m struggling to get the flywheel off ,the 14mm bolt is already out but it still doesn`t move

You will notice that removing the 14mm bolt reveals a bigger hole. Into this hole you screw a 20mm x 1.5mm pitch bolt to pop the flywheel off.

Rick O sells them if you cant find one at a local nut \ bolt place.

[marti]

hi, What years gsxr generators fit?
How much was the adaptor plate?
Did you get the plate direct from gforce?
Cheers

[Smev]

It's all in the thread - k7 gsxr - which is a 2007 model I believe!

I got one of the first ones from g- force - however a new cover is available from rick o.

All in it costs a load but makes the bike pick up like a 2 stroke!!

[RoninZX-10R]

It's definitely not a cheap mod (all up I think it cost about AU$200-250 for the G-Force adapter plate and another AU$100 or so for the GSXR alternator), but I think it's worth it, especially it you're racing the bike as it helps the revs pick up a lot quicker.
Like JC120 said, the original feels like it weighs a tonne compared to the Gixxer flywheel.