Postie's 'ohsix 600RR Rebuild after (someone elses) crash - 600RR.net
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post #1 of 389 (permalink) Old 11-08-2011, 04:28 AM Thread Starter
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Postie's 'ohsix 600RR Rebuild after (someone elses) crash

So, I should probably tell you the story of how I stumbled across this bike, before telling you the story of how its being rebuilt.

This bike had been crashed by it's previous owner and listed as a repairable-writeoff (ie, can be repaired and re-registered after a full vehicle identity inspection and roadworthy).

The previous owner managed to run all the way down the side panels of a brand new Subaru Forrester ($7500au damage) before dropping the bike and wedging it under the back of an old Ford.

He wasn't insured, and needless to say had a very hefty repair bill at the end of it for the forrester, and also for his bike.
(PUBLIC EDUCATION LESSON 1: INSURE YOUR RIDE) - or you end up getting

I picked it up for what I consider to be a bargain based on current australian '06 600RR sale values (however not as cheap as I would have liked), and I'm rebuilding it for the purpose of both road, and future track use.

Without further ado: Pic's of the wreckage










Watch this space.
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post #2 of 389 (permalink) Old 11-08-2011, 04:42 AM
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Watching this space... :)

Good to see you have the thread going mate!
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post #3 of 389 (permalink) Old 11-08-2011, 04:44 AM Thread Starter
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Nico, do you ever sleep/eat/*insert anything other than being on the forum here* ??
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post #4 of 389 (permalink) Old 11-08-2011, 04:45 AM
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sweet as! goodluck with project! enjoy!
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post #5 of 389 (permalink) Old 11-08-2011, 05:59 AM Thread Starter
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Work area

So, I figured I should show some pic's of my work area.

Unfortunately we only have a carport and not a garage, so I'm working undercover, but technically outdoors.

Organised Work Area:


The big fridge stores the bikes fluids & lubricants:
(The freezer also has both the CBR250RR and 03-06 CBR600RR workshop manuals)


The little fridge stores MY fluids :


And what workshop wouldn't be complete without an apprentice:

Last edited by Postie; 11-08-2011 at 06:01 AM.
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post #6 of 389 (permalink) Old 11-08-2011, 07:49 AM
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What a great use for a spare fridge! Great idea!
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post #7 of 389 (permalink) Old 11-08-2011, 08:27 AM
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Mate, that's rough.... you need help. You have your fridge priorities all wrong mate! Beer does not belong in the small fridge!

Quote:
Originally Posted by Postie View Post
Nico, do you ever sleep/eat/*insert anything other than being on the forum here* ??
I only sleep a little bit, maybe 4-5 hours a night. And other than when I'm at work I will usually be on here about every 2 or so hours... so essentially I'm on here regularly between about 5pm and 1am...
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post #8 of 389 (permalink) Old 11-08-2011, 08:37 AM Thread Starter
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Quote:
Originally Posted by Nico View Post


Mate, that's rough.... you need help. You have your fridge priorities all wrong mate! Beer does not belong in the small fridge!

I did consider this, but came to the conclusion that if I was going to need more than 30 bottles of cold beer for any one stint working on the bike... then I probably shouldn't be working on the bike!
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post #9 of 389 (permalink) Old 11-08-2011, 09:13 AM
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Your point, while sensible, is irrelevant!

Mind you, I only have a bar fridge in my garage as well... and its mostly full of paint.

Good looking boxer you have there as well mate.
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post #10 of 389 (permalink) Old 11-08-2011, 10:54 PM Thread Starter
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MOAR Pics

So the first step was to strip back what's left of the fairings, and do a thorough assessment of the damage.

Ok, so technically that was the second step. Step 1 was to dig into the grossly inadequate (thanks Nico) quantity of cold beer.

PUBLIC EDUCATION LESSON 2: LABEL EVERYTHING... EVERYTHING


For every bolt you remove, put it into a sealable sandwitch bag, and label it.
(Photo to come)

Nekkid:



Damage:

Will need to replace the rear fender eliminator (previous owners home job) with the original Honda OEM part to pass roadworthy again:


Cosmetic only, and not structural damage to front fork tube:


Crack in Right Hand Side Rearset & Bent brake lever.


The plug for the Tip Sensor was ripped off during the crash - this will need to be rewired:


The damage to the front fairing stay:


The Tip sensor has seen better days, and has all it's mounts broken.


In addition,
  • the RHS engine cover is scratched
  • The Clutch Cable Adjuster is broken
  • The ASV brake lever is scratched
  • Fairings are completely borked (duh)
  • Bar ends are scratched
  • Screws to hold the Front Master Cylinder lid are bent
  • Front Master cylinder lid is scratched
  • Front Speedo case is cracked
  • Rear Speedo Case has had its mounting points torn off
  • Will need original indicators (front & rear) for roadworthy
  • Dent in the radiator (not leaking though)
  • Grips have a slash in them
  • Clutch switch is broken off it's mounts

Now that I have it stripped, and I've identified all the broken bits, time to start cleaning while I wait for a few parts to arrive.
For cleaning trip, nothing beats Meguiars Gold Class Trim Detailer.


Oh, also: this came with the bike:
It's a Yoshi RS-5 slip-on, Stainless steel with a Carbon end cap. (don't you love Yoshi's "just spray it with expanding foam" packing method).

Last edited by Postie; 11-08-2011 at 11:24 PM.
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post #11 of 389 (permalink) Old 11-09-2011, 12:03 AM Thread Starter
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It's Alllliiiiiiivvvvveeeeeeeee!

It's Alllliiiiiiivvvvveeeeeeeee!




Changed the oil and Filter, drained and replaced the fuel, checked the air filter & airbox, and checked the radiator fluid.

It was turning over fine, but refusing to start, and then I realised that the tip sensor was missing and that consequently fuel wasn't pumping.

The whole concept of the tip sensor is to cut the fuel supply by stopping the fuel pump if the bike falls over onto it's side. Unfortunately if it' has been completely ripped off in an accident (like with mine) the circuit isn't completed, and the fuel pump doesn't work.

AHA! - solution, bypass the (missing) tip sensor.



Voila. It's running like a dream.
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post #12 of 389 (permalink) Old 11-09-2011, 12:35 AM
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Good work! Nico is a smart man, and as such, you should, no NEED, to switch those fridges around!

BTW, nice pup. We used to have boxers growing up. Such good dogs!

-Chad

"Logically, any motorcyclist can do 60* of lean. The trick is coming back up again." - Neal Spalding
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post #13 of 389 (permalink) Old 11-09-2011, 04:28 AM
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Good luck with the repairs! How much did you pick it up for and how much are you putting into it?
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post #14 of 389 (permalink) Old 11-09-2011, 04:43 AM Thread Starter
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Loom Repair

So I took the time after work tonight to repair the front speedo loom, and the ripped off tip sensor socket.

I'll need the tip sensor attached (and working) to get it through the roadworthy test, so I couldn't just permanently bypass the tip sensor (see previous post).

So this:


Should connect with this:



Red and Green are the two outside wires of the plug, with the white in the middle (if in doubt - match it up to the socket attached to the Tip sensor, which has matching wire colours)

The metal inserts to the plug can be removed with an very small jeweller's flat head screwdriver so that they can be worked on - before being re-inserted into the black plastic plug.

Instead of buying new metal pins, or trying to open and re-crimp the wires, I've just soldered the wires back onto the metal pins (or in the case of the red wire - soldered the two halves together, and then covered with heatshrink tubing.

*REMEMBER* place the green rubber seals (as shown in the pic below) back onto the wire BEFORE soldering the wire back to the pin. Otherwise you will end up like this --> and the rest of the forum will end up like this -->






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post #15 of 389 (permalink) Old 11-09-2011, 04:50 AM Thread Starter
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Nico & CBR6racr - We've had boxers all our lives. Fantastic dogs with a great temperament. Connor - the guy in the pic is an absolute champ.

He still has a way to go as an apprentice though, he's learnt to find my tools, but seems to confuse the bringing them to me part, with burying them randomly around the garden.

JGVasa - Picked it up for about $3000au, and should have it back on the road, fully repaired, including the Vehicle identity inspection & roadworthy fees for under $5000au total (ie $3000au for the bike, $2000au in parts).

They still sell for well over $6.5k here in Australia, so I consider that a bargain.

By far the most expensive part to replace is the fairings. I'll update this post soon with a breakdown of the costs.
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post #16 of 389 (permalink) Old 11-09-2011, 04:50 AM
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That trim detailer did an amazing job... and the bike is looking good so far.

Have a look at the chinese fairings mate, you should be able to pick up a set for around $600.

Last edited by Nico; 11-09-2011 at 04:53 AM.
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post #17 of 389 (permalink) Old 11-09-2011, 04:58 AM Thread Starter
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Nico - I've tried a lot of detailing products over my (relatively short) lifespan, but by far and wide, that Meguiar's stuff creams the rest (pun intended).

I've been looking at the chinese fairings, and can get a kit painted delivered for about $700 including a rear seat cowl)
I'll probably end up getting them from www.ozzymotorcyclefairings.com (I know Steve from the cbr250.com forums and may be able to get a discount)

But I guess now would be a good time to ask for opinions on paint schemes.. because I've spent the last week trying to decide, and I'm more unsure now than I was back then.

Go Go Gadget Suggestions!

(I'll update this thread with pics of my favourites once I've downloaded them)
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post #18 of 389 (permalink) Old 11-09-2011, 05:02 AM
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I know its not an 05-06 but I love the Konica Minolta

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post #19 of 389 (permalink) Old 11-09-2011, 05:13 AM Thread Starter
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Nico - Konica Minolta was at the top of my list:

05-06 shown below from www.ozzymotorcyclefairings.com
(I'd have to get the rim's re powdercoated in Blue though)



However, most people are telling me to get plain white.

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post #20 of 389 (permalink) Old 11-09-2011, 05:39 AM
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Well that's a bit boring =/

If there is one thing I can't stand its plain white cars and bikes...
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post #21 of 389 (permalink) Old 11-09-2011, 05:43 AM Thread Starter
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That's what I said.

I actually like the Konica Minolta from CBRfairings.com I think, the differences are subtle, but make for a slightly nicer look (or am I just being too picky)

Anyone had dealings with CBRfairings in terms of product matching website photos?



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post #22 of 389 (permalink) Old 11-09-2011, 05:53 AM
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Here is a couple of other places to look...

http://www.austmotorcycle.com/shop/c...RF5_05_06.html
$425 + $95 shipping...

http://cbrfairings.com/cbr-600rr-fai...ort=20a&page=2
$566.49 + $0 shipping... and they will sell you the solo cover, windscreen and bolt kit as well

http://www.auctmarts.com/main/
$529.99USD + $0 shipping

And they all use pretty much the same manufacturer in Hong Kong so there isn't going to be a lot of difference between them all.
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post #23 of 389 (permalink) Old 11-09-2011, 05:56 AM
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Quote:
Originally Posted by Postie View Post
That's what I said.

I actually like the Konica Minolta from CBRfairings.com I think, the differences are subtle, but make for a slightly nicer look (or am I just being too picky)

Anyone had dealings with CBRfairings in terms of product matching website photos?
I was visiting those websites while you posted this... but I don't think there is any difference between the fairings, just in the lighting of the photo maybe

There are a few reviews on here for CBRfairings, from what I remember they were good... just the standard fitment issues you will get with all of them. The other nice thing about them is that you can have them put a few extra coats of clear on for you...
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post #24 of 389 (permalink) Old 11-09-2011, 06:47 AM Thread Starter
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Thanks Nico, you're a wealth of information.

Fairings get ordered tomorrow :D

Does anyone have any suggestions on the best rearsets out there?

It's going to cost me $100+ to get parts for the RHS bracket & brake lever, and I'm thinking that $100+ may be better spent on a new set of aftermarket levers.
I'm going to have to get them off ebay too - because none of the wreckers here have any and Genuine Honda is just too damn expensive.

From what I know, Vortex rearsets are awesome, but will destroy the soles of anything shoes they come into contact with.

What would people do, would they just replace it with a stock rearset, or put the money towards a good set of aftermarkets, and if so, which ones?
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post #25 of 389 (permalink) Old 11-09-2011, 07:35 AM
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Stock ones mate, they need to fold to pass inspection and after market ones don't...

I would be buying one off here and having it posted over, should get here within a week or so if you fork out for express... pretty much guaranteed to cost you less than $100 as well....
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post #26 of 389 (permalink) Old 11-09-2011, 07:48 AM
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Have a look here:

lots o parts sale thread

He has a m/c + lever for $50, passenger pegs for $40

The forum you want to have a look through is this one:

http://www.600rr.net/vb/106-03-06-rr-parts/
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post #27 of 389 (permalink) Old 11-09-2011, 07:58 AM
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Oh, and you don't need the stock indicators, they just have to be a decent size with the appropriate globe in them, stockers are 21W. They also have to be mounted a minimum of 30cm apart. You should be able to find a fair number of second hand ones from ebay from various makes of bike.

With the fender, you don't need the stock one there either, you just need a fender that goes past a line drawn at 45 degrees like this (sorry about my lack of artistic skill):

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post #28 of 389 (permalink) Old 11-09-2011, 08:07 AM
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post #29 of 389 (permalink) Old 11-09-2011, 08:29 AM Thread Starter
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Thanks Nico,

always a legend.

I've already picked up a fairing stay and headlights from guys in the 03-06 parts forum - they should be posted tomorrow :D

Scouted most of the threads there, but the rearsets seem to be the first thing to sell (and especially the RHS).

There's an ebay auction thats' about to end with Rearset/MC/Line/Caliper going cheap that I'm keeping an eye on. I figure I can re-sell the Caliper/Line and MC, and get the rearset for next to nothing.

I'm throwing the stock fender back on because it came in the bag of spares with the bike and costs me nothing , as did 2 stock indicators and the other 2 stock indicators I picked up from a wreckers for next to nothing yesterday.

The only thing I have left to sort out is Mirrors, everything else is either on it's way, or being ordered this week :D
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post #30 of 389 (permalink) Old 11-09-2011, 08:46 AM
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