Topic: 2015 Yamaha FZ-09 Challenge 9 Track Bike Project

[SOHC4 Cafe Racer Fan]

New project -- convert a naked-style 2015 Yamaha FZ-09 (850cc inline triple) into a Challenge 9 style track bike.

What's a Challenge 9?  It was a French road racing series based on the Yamaha FZ/MT-09 with modified bodywork.

What did the bikes look like? 

mt11 by Donald Leonhardt, on Flickr

_DSC6117 2 by Donald Leonhardt, on Flickr

So here's the donor - a salvaged title 2015 Yamaha FZ-09 (resulting from a low-speed collision bending the front forks)

Untitled by Donald Leonhardt, on Flickr

After sourcing a pair of new forks, a used radiator, and a set of GB Racing engine cover guards for the clutch, alternator and water pump covers.

IMG_0510 by Donald Leonhardt, on Flickr

[ekpent]

 I've always wanted to take one of those for a spin and try it out. From the reviews and tests they seem to be a very capable and fun sounding hooligan bike.

[SOHC4 Cafe Racer Fan]

I've always wanted to take one of those for a spin and try it out. From the reviews and tests they seem to be a very capable and fun sounding hooligan bike.

The engine is the star of the show.  Lots of punch in a lightweight package.  It needs a little more weight on the front - hence the swap to rearsets and clipons - and this will help for a more appropriate track body position, too.

The stock suspension was also lacking, so that will be upgraded.

[emlupi]

They are great bikes, a real blast to ride. The triple engine has lots of character with good torque all across the range. Once it gets above 6000 rpm it’s a Jekyll/ Hyde personality. It wants to wheelie even if you don’t, especially in 1st or 2nd gear. Very light weight and agile, a great bike for the street.
Unfortunately, for me anyway, the seat was just too uncomfortable to bear for more than about an hour or so. Even an aftermarket replacement didn’t really help much so I traded it in. That shouldn’t make much difference for a track bike. Challenge 9 sounds like it ought to be a lot of fun. The FZ/MT-09 won’t let you down.

[SOHC4 Cafe Racer Fan]

Update:

To the donor, I installed the parts for the factory slipper/assist clutch for the 2015 XSR900.  This including disassembling the stock FZ-09 clutch, replacing the basket, changing several steel and friction plates in the clutch pack, and adding a new pressure plate.

Next, I discovered that the used stock radiator had a pin-hole leak, so I replaced it with an aftermarket radiator and guard. 

My paint and body friend Andrew "Paint by Bondo" Babish fitted the brackets for the front cowl, radiator guards and tail unit.

Untitled by Donald Leonhardt, on Flickr

Untitled by Donald Leonhardt, on Flickr

Untitled by Donald Leonhardt, on Flickr

Untitled by Donald Leonhardt, on Flickr

Untitled by Donald Leonhardt, on Flickr

We then removed the body work for a base coat of matte grey metallic paint, to add graphics later.

[ken65]

Good job.

[SOHC4 Cafe Racer Fan]

I removed the stock handlebar mounts and top triple clamp, and then installed new mounts allowing for more clearance for a GP5 steering damper, installed the damper and Woodcraft clip ons to allow for a 3" lower than stock handlebar position.  This combined with Woodcraft rearsets will provide a more aggressive track riding position and place more weight on the front tire.

Untitled by Donald Leonhardt, on Flickr

Untitled by Donald Leonhardt, on Flickr

Untitled by Donald Leonhardt, on Flickr

Also in the process of installing a Brembo 19RCS radial master cylinder.  I will be swapping out the stock 298mm rotors for 320mm Galfer wave rotors and 10mm caliper spacers to adjust for the larger diameter rotors.

[schwartzstuart6]

It's the engine for me

Sent from my SM-A107F using Tapatalk

[SOHC4 Cafe Racer Fan]

It's the engine for me

Sent from my SM-A107F using Tapatalk

Oh, I get what you're saying.  The engine is the high point of this bike.  The stock suspension is not so great, and will be upgraded.  I may decrease the rake a little (especially since I have a damper installed).

[SOHC4 Cafe Racer Fan]

Woodcraft rear sets assembled.  Unfortunately, the engineers at Yamaha decided that rear set changes would require removal of the swingarm pivot bolt, so I'll have to use a jack and relieve the weight on the swingarm pivot to remove and replace the rear sets.

Untitled by Donald Leonhardt, on Flickr

[SOHC4 Cafe Racer Fan]

Major upgrade. 

Ohlins S46 shock, Ohlins NIX30 cartridge kits for the forks, Graves Motorsports full titanium exhaust, and Woodcraft rear sets:

Untitled by Donald Leonhardt, on Flickr

Untitled by Donald Leonhardt, on Flickr

Untitled by Donald Leonhardt, on Flickr

[MauiK3]

Will it be street legal when done or will you race it?

[SOHC4 Cafe Racer Fan]

Will it be street legal when done or will you race it?

Neither. It will be a track day bike.

[calj737]

Don - The one change you might consider making is to lower the headstock. That is possibly the greatest change to the 2021 from prior model years. New model has the headstock lowered by 30mm. Reports are that it drastically improves front end handling.

[SOHC4 Cafe Racer Fan]

Don - The one change you might consider making is to lower the headstock. That is possibly the greatest change to the 2021 from prior model years. New model has the headstock lowered by 30mm. Reports are that it drastically improves front end handling.

Hi Cal,

Funny you should mention that. Yes, I've heard about this significant chassis change to the new bike.  Short of customizing a cast aluminum frame, I can mount the triple trees lower in the fork tubes, pushing the tubes through and lowering the front end. This is also one of the reasons I added a steering damper as the bike needs more weight on the front end -- it can feel light on the front especially above 115 mph.

[calj737]

...I can mount the triple trees lower in the fork tubes, pushing the tubes through and lowering the front end. This is also one of the reasons I added a steering damper as the bike needs more weight on the front end -- it can feel light on the front especially above 115 mph.

Yeah, with all the changes you're making to steering gear, and of course the challenges of altering the frame, seems like you're headed in the right direction. Didn't notice your choice of rubber?

[SOHC4 Cafe Racer Fan]

...I can mount the triple trees lower in the fork tubes, pushing the tubes through and lowering the front end. This is also one of the reasons I added a steering damper as the bike needs more weight on the front end -- it can feel light on the front especially above 115 mph.

Yeah, with all the changes you're making to steering gear, and of course the challenges of altering the frame, seems like you're headed in the right direction. Didn't notice your choice of rubber?

Thanks, Cal.  I'm going with Dunlop Q4 tires.  I've used them on track on an MV Brutale and Ducati 748, and was impressed with the grip level especially with no tire warmers.

[calj737]

No doubt! Super sticky shoes they are 

[SOHC4 Cafe Racer Fan]

More progress.  I lowered the front forks by 30mm to increase weight on the front and sharpen handling.  I also drilled locator holes into the clip ons for the stock throttle and start/stop/throttle map controller, and installed bar ends and a brake lever protector.  I also installed some Renthal grips.

Untitled by Donald Leonhardt, on Flickr

I had to hold off on the rotor upgrade because I still need to mill off 1mm off the caliper spacers (to fit the calipers up to the larger diameter rotors).

[river]

Excited to see this come together but, I must admit, I'm a little sad to see the streetable FZ you had go bye bye. That bike was really sharp. This should be rad too though.

[SOHC4 Cafe Racer Fan]

Excited to see this come together but, I must admit, I'm a little sad to see the streetable FZ you had go bye bye. That bike was really sharp. This should be rad too though.

Thanks, Chris.

Even with a project like this, there are always hiccups when you deviate from "stock" as you can attest from building you new rear end for the Squirrel.  It's nice when it all just drops in, but also satisfying when you figure out the solutions (as long as that process doesn't cause too much brain damage).

[SOHC4 Cafe Racer Fan]

The bike is off to the tuner.  I'm swapping in a Flashtune ECU.
The flashed ECU does the following:
Installs a exhaust specific map, tunable with a Dyno
Fuel injector proportioning
Ignition timing
Immobilizer function
Cooling fan temps (lowers threshold)
Rev-limiter control (removes soft limiter)
Removes top speed limiter
ECU based quick-shifting with additional quick-shifting hardware (e.g., Translogic quick-shifter)
Speedometer calibrations

The ECU is already tuned to my Graves Motorsport full titanium race exhaust.  It will make approximately 131 hp with the tune.

I am also installing a Translogic quick-shifter for clutchless up shifts and auto blipping downshifts.  This helps quicken acceleration and on deceleration decreases chassis upset from downshifting.  I've used this exact same set up for aggressive canyon riding and it is makes the bike so much easier to ride harder.

[SOHC4 Cafe Racer Fan]

Got the bike back from the tuner.  It's making noticeably more power -- even punchier -- and the quickshifter is functioning well.  The autoblipper downshifted is seamless.

Untitled by Donald Leonhardt, on Flickr

Oh, and I added a Graves front sprocket cover.

[Nicklopic]

I like where this is headed and seems like it will be a blast!
Following lol

[SOHC4 Cafe Racer Fan]

The electronics are sorted and most of the mechanical elements of the track bike are done.  The bike is back in the hands of my painter to paint the base color of the bodywork (dark charcoal metallic) and lay out graphics (some red and light gray/white).