Hi all,

I'm trying to build the lightest '07 S2R 800 I can without BST wheels.  I've done the following:

Rear end:

Ti axel nuts
Ti sprocket nuts
Quick change sprocket, 520 chain, 14t front sprocket
Alu flange
CNC Racing caliper carrier
Beringer alu caliper (440 grams - lighter than Brembo CNC caliper, but I'm sure there's a lighter caliper out there?  Don't want to get into custom mounting, so it would have to fit the stock bolt pattern)
Braketech Iron rotor
Ti rotor bolts
Forged Marchesinis (Don't want BSTs or mag wheels - don't like the look of BSTs, and don't want the maintenance hassles of mag wheels)
Penski shock
Ti shock spring
Ti shock hardware
Ti swingarm pivot bolt
Chain guard delete
Plan to: replace stock height adjuster with aftermarket one

Front end:

TPO Alu axel
Ti axel nut
Ohlins R&T
Braketech rotor
Ti rotor bolts
Ti caliper bolts
Brembo four piston caliper (will upgrade to radial)
one caliper, one rotor delete
CNC Racing triple set
Beringer MCs with integrated reservoirs
CC Clipons
Ti steering nut
CF headlight wings

Body:

ETI Fuelcel tank
CF seat cowl
CNC Racing rearsets
Passenger peg delete
Passenger grab bar chop
Passenger peg mounting tab chop
Tail chop

Electric:
TPO kickstand switch eliminator
Integrated tail light
Earth X Lion battery
Plan to: Full Motogadget rewire, to include mini speedo

Motor:
Ti Arrow full system
Airbox delete, pod filters
Planning to: crank, flywheel, primary gear lightening, etc.

Am I missing anything obvious?  I haven't weighted the bike yet, but I'm trying to get to around 360lb wet.  

Diet and exercise

Quote from: memper on June 28, 2014, 05:10:36 PM
Diet and exercise

I've got that covered, too 

I admire your commitment to "light is right".
I'll be following this tread closely.
The Nichols flywheels are reputedly the lightest. Some delete the airbox and run pods with velocity stacks, but this apparently requires extra tuning in most cases. Maybe a lightweight dry clutch conversion if it is a wet clutch model. Not straightforward from what I've read. Also a carbon headlight bucket and ring and carbon bars.
Be great to see the final weight.
Cheers.

Quote from: koko64 on June 28, 2014, 05:18:01 PM
I admire your commitment to "light is right".
I'll be following this tread closely.
The Nichols flywheels are reputedly the lightest. Some delete the airbox and run pods with velocity stacks, but this apparently requires extra tuning in most cases.
Cheers.

Thanks!  

I forgot to add that - yeah, I'm running pods.  I've got an Arrow Ti full system as well.  I also deleted the mirrors and front hugger.  

I think I can cut around 10 lbs from the motor by lightening the gears and crank, and I hear there a few pounds lost if you rewire, especially if you use Motogadget stuff.  Though I am in complete awe of Stradafab's craftsmanship and would love a Ti frame, I don't want to get into the headache of trying to title or insure a custom framed bike.  

Maybe alloy adjustable cam pulleys (and you can get your cams dialled while you're at it), and carbon cam belt covers. Otherwise I got nothin', because you have covered just about everything. You might want to personal message Kopfjager, because he has also created a very light bike.
Cheers

What have you got for a pressure plate/clutch cover combo? Could shave off a couple of grams there.

And I don't know what, if anything, ever happened to it, but at one point Duc Stu was working on an aluminum rear subframe. Required chopping the frame just aft of the motor.

Stradafab titanium frame and exhaust.

Minor threadjack, how'd you get an ETI Fuelcel for the S2R? I had contacted them while ago when my last tank expanded and they said they are not making them for the S2R only for the older carb bikes. 

Quote from: koko64 on June 29, 2014, 01:13:33 AM
Maybe alloy adjustable cam pulleys (and you can get your cams dialled while you're at it), and carbon cam belt covers. Otherwise I got nothin', because you have covered just about everything. You might want to personal message Kopfjager, because he has also created a very light bike.
Cheers

I've got some alloy pulleys installed    But no cf belt covers - I'll check those out.

Quote from: Buckethead on June 29, 2014, 07:19:34 AM
What have you got for a pressure plate/clutch cover combo? Could shave off a couple of grams there.

And I don't know what, if anything, ever happened to it, but at one point Duc Stu was working on an aluminum rear subframe. Required chopping the frame just aft of the motor.

The 800 has a wet clutch, so not much I can do there.

Quote from: hackers2r on June 29, 2014, 08:10:42 AM
Minor threadjack, how'd you get an ETI Fuelcel for the S2R? I had contacted them while ago when my last tank expanded and they said they are not making them for the S2R only for the older carb bikes.  

I gave them a tank to pull a mold from, which means you should be able to get one soon!  

While the motor's open, Ti valves and rods.
Pistal likely has some hi-comps that are lighter than stock.
Someone here (DubLuv?) Has been busy lightening most of the engine internals.

An older non-APTC clutch may be lighter.

Magnesium alternator cover.

Dub Luv really Swiss cheesed those parts.

I'm liking this thread. I like to see what's possible when someone is committed to a concept.

You are missing pictures  
TPO Ti rear brake actuator rod?
I had to get one when I went with rear sets making my stock one too short.
carry on with the good work  

Quote from: Speeddog on June 29, 2014, 12:40:24 PM
While the motor's open, Ti valves and rods.
Pistal likely has some hi-comps that are lighter than stock.
Someone here (DubLuv?) Has been busy lightening most of the engine internals.

An older non-APTC clutch may be lighter.

Magnesium alternator cover.

I didn't think anyone made pistons or rods for the 800 motor - I have seen them for the 900 though.  I like the mag cover idea.  

Yeah, I've been following that thread closely - lots of great ideas there!  

Quote from: koko64 on June 29, 2014, 06:06:55 PM
Dub Luv really Swiss cheesed those parts.

I'm liking this thread. I like to see what's possible when someone is committed to a concept.

Thanks!  I have learned that Ti is not necessarily the lightest option - aluminum is more often than not lighter when it comes to fasteners. 

Quote from: Duck-EZ on June 29, 2014, 06:14:07 PM
You are missing pictures  

I promise to post lots when it's finished

Downsize the rims?

Tire choice?

Single front brake rotor?

Breather delete?

Getting pretty exotic, but were CF swingarms available for the S2R?

BK