Project Polar-Raptor

[V4mp]

Great Job!
Just one question, have the wheel base increased with this swingarm?

No, it is decreased.

[V4mp]

After third layer of black paint.

[Crap Tartan]

engine looks good, be nice to see it back in the frame?

It could be a bugger when you need to unbolt or remove anything from the engine tho`.................................

[V4mp]

engine looks good, be nice to see it back in the frame?

Hopefully in couple of weeks.

It could be a bugger when you need to unbolt or remove anything from the engine tho`.................................

I know..

[V4mp]

I haven't reported bikes progress for a while...
Because of my new job, I had to move to other city and I got time to fix bike only in weekends. Also my girlfriend is slowing me down, she doesn't like the idea that I'm spending whole weekend in garage... Can't always understand women.

Two weeks ago I got engine back into frame.



Here is picture after last weekend.



There haven't been any major setbacks with rebuild before last weekend.
Last weekend I realized that exhaust won't fit and I can't you use my new R1 forks with stock yokes.

[Crap Tartan]

Obviously why wont the exhaust fit and why wont the R1 forks fit your yokes?

Just I have previously done similar changes without issue................

[V4mp]

Why won't the exhaust fit

Because in MV Agusta swingarm there is place for the exhaust pipe on the right side like in picture above (Panigale). Cagivas stock exhaust routing goes closer to the center-line of the bike and will hit the swingarm.

Why won't the R1 forks fit your yokes?

Well I'm not 100% sure, because I haven't tried them yet. But I have made some quick measurements and it doesn't look good.
I think the problem is this if I use Cagiva yokes/R1 forks/R1 wheel+brake discs combo brake discs will hit brake caliper. How I came to this thought?
Let me explain, in R1 yokes forks are ~5mm further than they are in Cagiva yokes (How I know this? When I bought R1 forks it came with lower yoke) which moves brake discs ~2,5mm outwards.
Only thing which can safe me is that there ~2,5mm excessive space in caliper where brake disc can move.

[Crap Tartan]

Well I am unfamiliar with the MV swinger so cant really comment but am surprised that the rear downpipe would ever have fitted with the swinger in the first place?

I have R1 forks/brake discs/calipers and modified spindle with custom spacers married to my standard raptor wheel and yokes. I had to space the calipers by around 1mm each side to align with the discs. Of course this may be dependant on what year R1 parts you used as they may have changed certain things and dimensions. Mine is from a 99 4XV model.

The R1 yokes size is irrelevant as you are not using them or the R1 wheels, the variables are the raptor/R1 disc offset and the caliper alignment. All this is solved by the right spacers on the spindle and the small spacers I made for the calipers.

[V4mp]

Well I am unfamiliar with the MV swinger so cant really comment but am surprised that the rear downpipe would ever have fitted with the swinger in the first place?

I have R1 forks/brake discs/calipers and modified spindle with custom spacers married to my standard raptor wheel and yokes. I had to space the calipers by around 1mm each side to align with the discs. Of course this may be dependant on what year R1 parts you used as they may have changed certain things and dimensions. Mine is from a 99 4XV model.

The R1 yokes size is irrelevant as you are not using them or the R1 wheels, the variables are the raptor/R1 disc offset and the caliper alignment. All this is solved by the right spacers on the spindle and the small spacers I made for the calipers.

Well mine is from 2007-2008 R1.
It has radial mounted calipers, which makes things little bit harder.

[V4mp]

After a another weekend...





Finally I got to a point where I was able to start the engine!
Happiness did last a second or two because oil pres./water temp. light and FI came into dash... I haven't time to start search where problem was.

Next weekends job is to put Raptor in "dealers mode" and hopefully error code tells me where to start looking for a problem.
Other thing that needs to be done:
- Add brake fluid
- Make brake fluid reservoir
- Engineer rear brake and rear wheel spacer
- Mount fairings
- Make sure everything is tighten

[Dante]

Are you gonna keep the stock fork?

[V4mp]

Are you gonna keep the stock fork?

No, changing it to R1 forks.
Just have to figure out how I'm going to do that.

[V4mp]

Before shakedown I added brake fluid and bleeded front brakes. Front brake works!
Installed some fairings and front indicator pods, removed rear wheel spacer.

Belly pan brackets needs some fixing before belly pan can be mounted, not a big job. Right frame infill can't be mounted before I figure out where to put rear shock piggypack.
Bigger problem is how to mount air ducts and front fairing... Old "nuts" broke when I removed them, and OEMMotorparts didn't have them, any ideas?

Also I did found and resolve what caused FI on the dash,one of the front throttle body wire were broken.

Then shakedown!
Almost everything seems to work!
What is not working?
- Speedometer
- Rear set footpegs are too short, hard to change gears.

Other thing, needs to be done:
- Rear brake
- R1 forks

Pictures after shakedown.

[V4mp]

Polar-Raptor is now in ride able shape!

Speedometer started working after cleaning actual sensor and making sure sprocket cover was tightened and placed correctly.
Bike rides pretty nicely, only thing that really irritates me is how stiff rear end is. Looks like I've to change rear spring to softer one.
The question is how much softer, I think I need suspension specialist to answer that question.

Bellypan and swingarm cover are still waiting to be fitted.. What else?
R1 forks are also waiting for mounting. I need to take some measurements and make a plan how to fit them...
Mmm, there is also the same old rear caliper issue and rear shocks piggypack haven't found better place to be yet.

Here is couple of pictures how it currently sits. If you want to see more, check out my google drive!

[gilbert666]

You will have to bulit another exhaust for the swing arm, I started one when I tried to mount the mv agusta mono.

I still have the rear exhaust part and some front parts to complete your exhaust if you need it.







if it can help....