one down ?? up

[dagdowell]

thanks a lot Scott. I'm interested to know how your install goes for you as I don't know the first thing about replacing chains/sprockets. I've been going back and forth between doing just the 15T or the whole 520 conversion.

[Bnonn]

I'll be interested to read the write-up. How much increased low-end power is this likely to result in? I mean, between a stock FZ6 and a modded one, what sort of difference should one expect in a 0-60 time, or a quarter-mile?

[koozi]

Well, FINALLY, the 520 conversion kit showed up this afternoon. I ordered it on 3-5 and it showed up today 3-21. I am not thrilled with sum of all parts, we have talked and e-mailed several times--not the best vendor IMO.
Enough of that, I do not want to turn this into a whiney thread.
I ended up getting the 15/48 combination--not the 15/50.

It took about an hour to install the new sprockets and chain. I did not even put the bike up on the work bench, just used the center stand to raise the rear wheel. First thing I did was pull the chain guard off; I don't have a hugger anymore so that was just two 10mm bolts.
Next I pulled off the CS cover--3 allen bolts, 6mm, I think.
Next was the counter shaft sprocket nut, it requires a 32mm socket to remove it. I used an air impact wrench. Although it is probably not required it is certainly much easier.
Then I pulled the rear wheel off, I used the 32mm socket on the air gun for the axle nut.
The factory 530 chain does not have a master link so I cut it with an angle grinder. I usually grind the rivets down and press a link free but I was anxious to try this upgrade so I just cut down through a link this time.

After the wheel was off I put it on my tire changing stand—really a keg with the top cut out and a towel thrown over it for scuff protection. The sprocket is held on with 17mm locknuts.
Old sprocket off and new sprocket on, then the new counter sprocket put on. Be sure to reuse the fold-over lock washer, better safe than sorry on that. The CS nut is designed to go on with the hollow part towards the bike.
After installing the two sprockets I put the back wheel back in place but left the axle only loosely bolted in place. At this point you need to be able to easily slide the wheel assembly to get everything lined up correctly.
Next the new chain, I cleaned the factory packing glue with some mineral spirits and then sprayed it liberally with WD-40. I hooked the chain over the top of the rear sprocket to keep it off of the ground and slid it around the CS sprocket and then back to the rear. Do not wrap it around the bottom of the sprocket yet because you need the slack. Do hook the end of the chain on the top of the sprocket to hold it together so the master link can be installed.
Installing master links on x and o-rings can be a challenge. I have seen welded up contraptions to try to make it easier but all you really need is a pair of vice grips and some patience. Be sure to put the provided x-rings in place then slide the link through the ends of the chain, connecting them. Put the two remaining rubber rings in place and then the outer plate. Using the vice grips on the very outer edges work the plate on tight going back and forth on only the very outer ends of the plate—outside of the pins. After it is down tight slide the clip on using needle nose pliers. Be sure the open end is facing the front of the bike when the master clip is on the top of the chain loop. It would be possible to fling the clip if you have it facing the other way. It would suck to have your fancy new chain sliding down the road because it was installed wrong.

Now comes the only really challenging part of the whole install, lining up the wheel and sprockets so the chain runs straight and true. The marking system on the FZ6 is lame. There are marks to use but they are on the slider inside the swingarm and the two washers on either side of the axle are different sizes so it is more aggravating than it needs to be. My dirt bike is much better thought out! I ended up using a combination of the marks, a yardstick and my eyes to get the wheel and chain tightened just right. This process took more time than any other part of the install, but it is important to get it right.
After the axle was in the right place and tightened down all that was left was to re-install the chain guard and CS cover. Then it was time for a test ride.

I was really excited to see how the pulling power was compared to stock and how the revs compared to stock at cruising speeds. I have not done the speed healer yet so I was also interested to see indicated speeds.
I can safely say I was not disappointed! I only rode about 20 easy miles but based on pacing traffic I believe 55-60mph of real time speed indicated 75-78mph on the speedo.
Cruising at 60 in 6th gear before was around 5k on the tach, now it was dead on 6k. Gaining speed to pass while cruising is much easier now, no need to downshift like before, turn the throttle and go.
Acceleration is clearly stronger because it is in the powerband sooner. I do have to shift more and I can tell that gas mileage is going to drop. I will post up after a tank or two to share real mpg differences.

All in all, as of now I am very pleased with this gearing change and the 520 conversion.

[jcaesar]

Good write up Koozi. Do you have any photos of the installation steps to go along with it. I'll add your Sprocket Change to the How To's in the sticky'd "FZ6 Topics Worth Linking".

[jcaesar]

Here is a thread that was in the sticky'd "FZ6 Topics Worth Linking" thread. It has additional reviews on the 520 conversion and discusses 15/48 vs. 15/50.

http://forums.sportbikes.net/forums/...d.php?t=276066

[koozi]

Thanks JC
No pics. I really did not expect to see the kit today so I left the camera at school. Then when I saw it had been delivered I went ahead with the install. Had to do it

Next time!

[koozi]

I hit a snag with the SpeedoHealer install. I have the Universal kit instead of the Yamaha plug in kit, exactly as I ordered. Yep I messed that up... That means to use it I would have to cut wires in the harness--no thanks.

I e-mailed Cal Sportbikes, the SH reseller for the USA and explained my problem.
http://www.calsportbike.com/
Within 24 hours, on a Saturday night at almost midnight, I had a reply offering an exchange. I called today and got the RA# and talked to Todd, the owner, for quite awhile. He is good people. He knew about FZ6s and riding in general.
I wish all vendors were as willing to be kind to customers as Todd is. He even cross shipped the right cable with the one I am returning so that I will get it sooner.

Although, I admit it is a rush to see 80mph on the speedo and not worry about getting a ticket on the roads around here, cause I'm not really speeding

[fz6innh]

Nice writeup Scott. Thanx for sharing. I'm curious about how much healing is needed in realtime along with the gas mileage. Like you, I'm not one for hitting triple digits nor do I care about wheelies, but you hit the nail on the head with "hitting the powerband before the speedlimit" so I'm considering some type of change. Maybe not so much right up front... maybe just drop to 15 in the front to start and monitor changes.

Thanx!!

-Eric

[jwilliamsFZ6]

Here is my conv. experience
I did a 520 1 down 3 up conv. The bike tops out at 153 on gps(shows 176 on speedo). First run on a 1/8 mile drag strip it ran a 7.9. On the dyno I put 87 hp to the rear wheel and 47 ft/lbs.(can't remember rpm range, sorry).Still has factory air filter and muffler. Bike wheelies eazy, and gas milage sucks. All in all I love the conv.

[kevinmroczko]

Damn nice write up koosi!!! Thanks for all the detail!

[JamminJimmy]

Dagdowell,
I just bought and installed the 520 conversion kit from Sumofallparts that you are talking about a couple weeks ago. I don't have "hard" data, but as with what everyone else is talking about- there is a definite difference in "pull", etc.... No more downshifting to pass and much better off the line. I went 15/48(which is what they consider optimum for the FZ6) and the 520 chain. With a GPS, actual speed was 5mph slower @ 25 and 10mph slower at 55mph. Originally, I thought I was fine, but now will order a speedohealer- to eliminate estimating my speed(I'm simple-minded...). It was $151.94 including shipping to the Boise area. The order took a little longer because of several emails back and forth with them- but I was glad they took the time to make sure I got what I wanted.... I haven't looked at top speed, but don't really care about that. I would definitely do it again, even though I'm a cheap b?stard and don't want to pay for a speedohealer....

[ktravelet]

do we have any gas mileage reports?

[FZ1-KEP]

Originally Posted by ktravelet

do we have any gas mileage reports?

When I did the 520 conversion, 15/48, my mileage dropped about 2 mpg. IMO it is a worthwhile mod, but not necessary.

[Jeff d]

I've considered going the opposite way (Up in front and/or down in back) for increased fuel efficiency.

Anyone done that? If so what kind of MPG increase did you see?

If I could spend $20 or so for a 1 tooth larger front sprocket and get 8-10 more MPG that would pay for itself pretty quickly being that I'm a commuter.

[DefyInertia]

Originally Posted by Jeff d

I've considered going the opposite way (Up in front and/or down in back) for increased fuel efficiency.

Anyone done that?

TourGuide did that. Talk to him.

Originally Posted by dagdowell

165 is very doable in Idaho;

Indicated...that must take forever!!!!!!