Wheel + Swing Arm Mod

FZ-16/FZ-S Wheel + Swing Arm for R15

So, This part of the modd deals with replacing the R15's wheels with the ones of FZ-16.

P.S. : The wheels and the Swing arm for an FZ WOULD NOT BE a direct fit for the R15 and has to be customized accordingly.

The cons of this modd would be:

• The height of the bike would increase tremendously (short people please don't go for this modd as your feet wouldn't touch the ground).
• FZ-16 has no Rear Disc brake. This implies the wheel rim has no disc and the swing arm doesn't consist of the disc brake pad assembly.
• FZ-16 has a basic mono shock while R15 has a linked type mono shock (advanced).
• Reduced mileage and handling.

The pros of this modd is:

• Fatter rims and wheels and a better looking swing arm + hugger.
• No other pros - This is just a waste of time if you have lots of time to waste. The whole customisation is just for the bike to look better.

If you ever wondered what would be the cost of all the parts, the approx is as follows :

FZ16 Rear Rim + the tyre = 5K

FZ16 Swing arm = 2K
FZ16 Shocks = 2.5K

FZ16 Front Rim + the tyre = 3K

Pictures of Few parts I bought...

• FZ-16 Swing arm + Mono shocks (spring)
• Bought a silencer/muffler/exhaust pipe which i will fix under the seat. This silencer has a nozzle to toggle between free flow (loud sound) and the normal flow (no sound).
• Front Twin Disc - Bought a Disc and calliper to act as twin discs
• A longer Chain ( FZ Chain), FZ Sprocket Holder, Front+Back Bearings, Front+Back Axel, Chain Adjusters
• Front Wheel Odometer Plug for FZ
• Pirelli Diablo Z  160/60/17. Wont be buying an FZ's front tyre as the current rear tyre of the R15 is the same size as the front one of FZ but a little fatter.

If you ever need imported fat tyres like Dunlop, Pirelli, (& lots more) for a cheaper price.

Contact.. (+91 9448708513)

Mahesh Kumar - Tyre Junction

 

Methods:

Wheels  : (Has to be done professionally using a CNC Welding Machine)

• Front Wheel - The front wheel cast/rim of FZ is broader at the center where the axle sits. R15 does not have boader telescopic shocks and hence it would be impossible for an FZ front rim to fit in between the telescopic shock absorbers. Since this modd involves Front Twin Disc brake assembly, the following has to be done. The right side of the Original R15 front wheel cast is cut at the center along the axis in order to slice out the whole side that holds the disc brake. The FZ front rim is sliced similarly on the left side along the axis. Now the Right side of the R15 front rim is welded on to the Left side of the FZ rim hence making it thinner at the center than before and now the result would have both the sides with the provision for disc brakes and a perfect fit into the thinner telescopic shocks of R15. The photo shows the front wheel with twin discs. If you dint notice, the silver part on the rim is the original R15's part chopped and CNC welded on to the black FZ's rim on the left side. P.S. This whole procedure should be done only with a CNC Welding machine.
• Rear Wheel - The only modd for the rear wheel is fixing a Rear disc brake onto the FZ (drum brake) wheel cast. The same method above for the front wheel is applied here too. The right side of the R15 wheel (that holds the disc) is chopped and CNC welded onto the new FZ rear wheel. If you dint notice, the silver part on the back rim is the original R15's part chopped and CNC welded on to the black FZ's rim on the left side.     

  

 

FZ Swing Arm :

• I dint have a photo to describe hence drew one. Fig A. is R15 swing arm. Fig B. is FZ Swing arm. Fig C. is the modified swing arm. The top part of the R15's is cut and welded on to the top part of the FZ. Likewise, the middle part of the FZ swing arm holding the spring is cut on either side to bring the upper ends closer.

 

Front Left Telescopic Shocks : (Front twin Disc Brake)

• In order to hold the LHS Side Disc brake calliper, this modd is done.

Spring Placement :

• The bottom end of the Sping is mounted on the Swing Arm, The top end is mounted onto a holder which is welded on the frame at this particular position as shown in figure. Red shows the Swing arm and the clamp that is welded onto the frame. Blue is the Spring shock absorber.

Pictures at Workshop..

Final Pictures..

Painted the disc callipers black. (looks better)