Building a 650R / ER6 subframe

Kawasaki kept costs low by making the frame and subframe on the ex650 or er6 all one piece. I took it upon myself to build my own aluminum subframe to reduce as much weight as possible.  This was probably more work than what it was worth, but I managed to build something I am very proud of and I wouldn’t have been happy with it if I would not have tried at all.

1902 Hendey lathe being used 100 years later on an kawasaki ninja 650 ex650r race bike

 

Milling flats onto the subframe brackets Subframe mounting brackets will be welded to the subframe tubing and bolted in place using Yamaha R6 subframe bolts 6061 aluminum. Kawasaki ninja 650r er6
Milling flats onto the subframe brackets Subframe mounting brackets will be welded to the subframe tubing and bolted in place using Yamaha R6 subframe bolts 6061 aluminum. Kawasaki ninja 650r er6

 

 

Subframe mounting brackets will be welded to the subframe tubing and bolted in place using Yamaha R6 subframe bolts 6061 aluminum. Kawasaki ninja 650r er6
Some corners need to be rounded off, but I feel they turned out better than expected. The turned down area will fit inside the tubing used for the subframe, and will be welded in place.

I made the tail section tube replaceable in the event of a crash.  Instead of having more leverage to bend the subframe. I am hoping it will only bend the single tube in the back.

The finished aluminim subrame bolted to the Kawasaki ninja 650 ex650r 650r er6
The finished aluminum subrame bolted to my 650.

Chad

Riding motorcycles and wrenching since my preteen years, I have moved from motocross to street bikes. Being a teen back in those days it was tough to get me off of the bike. Now days even though I am very busy being a dad I still have my weekends and go to the track to race and on occasion will do a track day or two.

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