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hmarginson's bike rebuild and mod beginning

9K views 79 replies 9 participants last post by  hmarginson 
#1 ·


ok so, i've had my 2008 rr a little while bought on only 5k miles, nearly had her a year, had a small spill on it,ripped a hole in the swing arm and got a scuff to the tail...
so i fitted a new, freshly powder coated swinger...sorry its dirty lol

and also had the dreaded charging issues.

the charging issue was solved as normal, aside from the flywheel demagnetising on one side, causing low voltage even with a working stator and regulator again.

here's how she looks now...

got a power commander for it, also got some arrow race headers and it's having a custom made end can, but i need to get the money together for that first, so for now, i shall just fit the power commander and the O2 eliminator to the bike in stock trim...

first i started with getting to this stage... opting for ease of access over time constraints. a simple enough task for anyone as i'm sure you're all aware.

time to tackle getting the tank cover off, nowhere near as simple a job as i thought, having had a daytona 600 beforehand, that was easy, since it was just a plastic tank and that was it... however, success!



with this done, time to get the tank out of the way enough to get at the lower injector connections, since theres not enough room to swing a cat in there as standard
 
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#2 ·
of course, doing this solo, the tank needs propping, and the age old 'a hammer fixes everything' comes into play


now under the two hoses there are to grey clips, and then two level with those outside of the hoses, these are the ones to unplug and plug the corresponding PC3 plugs into, for the ones to the right of the picture, i found going in from the top was the easiest way for me personally as they're in a bit of a **** place, I had to get pliers on the inner right one because fingers are too fat. the PC3 plugs are easy enough, the shortest wired plug is on the left, the longest on the right, this means the throttle position sensor plug is on the left too..leading me onto this..

and behind that bracket lies this...
<
with this done from underneath there is now a mass of PC cables, resembling this shoddy picture...


time to put her back together, just retracing steps as normal to end up here...
tucked away nicely until i get the new system on, lose the flapper and store the PC there in its place, I forgot to take pictures of the O2 install, but that's such a simple wire trace (though the plug is a bastard to unplug) that there not much point going back for pictures sake.

I've got a few parts on order due to arrive in the coming weeks, nothing major, but pictures will follow anyway, eventually the plan is to lighten the bike as much as possible whilst remaining road legal, it's becoming a fast weekend track attack tool, but since i commute (usually on the dizzer) having lights is a must as sometimes it's at night, but this will be very rare all being well.

I have a track day coming up at oulton park shortly so theres some additional crash protection coming and I've now got sliders since i trashed a pair of kevlar jeans in an off...i've been getting some practice in on them ready, any tips welcome for this..

until more things arrive, here's a picture of it looking pretty, and also the workhorse/wheelie machine

 
#3 ·
i thought i had a shot of the headers... I got them second hand as a steal, haven't figured out how to construct them as I haven't really looked, they're dirty as hell but i've had a dremel with a little mop on cleaning them slowly, so they're getting there slowly, the end can will be as mentioned a custom made job by a guy who makes race exhausts for the local clubs, meaning they're quiet enough for noise regs on track, but at the same time squeezing as much power as possible, he also then sets a custom map up for you to make sure it's all dialed in properly...it will cost less than an akra slip on all in, but i've checked out his work, seen the guys bikes he works with, it's good stuff, very good stuff, he just prices realistically instead of paying top buck for a brand... (though if an akra came up cheap, i'd be tempted).

I do need help identifying which headers they are though so i'll build them up and grab a picture in case any of you guys can assist, as soon as the next bits are in, I'll get to work on posting that too
 
#4 ·
ok, grabbed some pictures of the headers, as you can see, a bit grim, but the autosol process has been started, though digging around on here i've found out about optiglanz so i'm going to get some of that and get them cleaned up, theres also a rusty mid piped ducati that will love this stuff

i had a go at mocking them up into shape but they don't really look right, obviously once i get round to fitting them with the can im still yet to sort, I should be able to make the fit up, but if anyone can point me in the right direction so I have it set out correctly, it'd be appreciated...
 
#6 ·
cheers, that's the plan, I get paid friday so i'll be ordering some in...just gotta figure out how they fit together, see if i can save myself some fitting costs when i get this custom end can, i've found some tasty carbon treats i want to get popped on too in time, and im still in two minds about how i wanna tail tidy it, i want the undertail tail light and then more flush indicators, im wondering if the carbon undertail from tst could be cut into to fit some flush mounts underneath, eliminating the flappy indicators, without screwing up MOT capabilities from an IT.... i may need to ping them an email :D
 
#7 ·
just a mini update, my headlight protectors arrived, nothing major, but i think they look pretty cool, a bit meaner anyways

not that i'd ever have them fitted at night, but gotta admit, it does look pretty cool in the dark...
 
#8 ·
Well, disaster has struck yesterday,I'm laid up in hospital...
And my poor baby,well...


So damage is mainly superficial,subframe and fairings, two engine casings,and rh bar,time to turn it into a super light track bike, accident was my fault,wasn't going fast but fucked a bend that I do every damn day without issues took out another biker who is perfectly fine,has less damage to his older cbr600f, I'm TPFT so will get jack from the insurance but you live and learn,main bit being the live part lol
 
#9 ·
My damage report is one totally smashed index and knuckle,middle finger is another break and broken knuckle, my wrist is dislocated and my hand is fractured,I have a 4cm laceration on index finger which is down to the bone, it's gunna be 2 months to ride again and 6 months before I can box anymore :/
 
#12 ·
It's mainly superficial I'm told, hand specialist says I however am fucked, I may never regain full functionality and may never box again, I'm a bit devastated but I'll fix the bike for now, already got parts priced up, insurance have said no payout so we'll see what happens from here, cant do **** until I'm out of hospital :/
 
#13 ·
ok ive had chance to get some proper pictures of my gear etc. as you can see, the rightglove was ripped open, which is the obliteratedchand, but the left glove took more damage and that hand is fine :/ my lid did it's job but my gear is scuffed and bloodied too, shame but my pants and jacket can be re-used.






 
#14 ·
looking at the bike damage, we have damaged radiator, one casing/bottom end, subframe, all fairings pretty much, but, its salvageable, new rad, bottom end and subframe and she's rideable lights will be removed and a track monster will be made...








 
#15 ·
my haynes arrived today, so the strip down has begun, bearing in mind i only got about an hour of time to spend on it, with one hand,, whilst trying to fight with the bike getting on the damn stand...

however i did manage to get this far

i also had my optiglanz delivered, which after getting half the headers to this stage over 2 hours, a dremel and lots of autosol...

i've managed in just 10 minutes with a few bottle sprays and no need to fumble onehandedly scrubbing, they now look like...


this is progress i'm very happy, i just need to get the dremel and autosol back out to really finish making it gleam :D
since i need an end can, i spoke to the guy making my exhaust, he said he's too busy for my business right now and he just hasn't got time, so, i took to ebay bargain hunting, came accross this...which incidentally is immaculate too :D


i'm rather pleased with myself so far :D oh and it turns out the subframe is actually just twisted a bit, so i'm going to get someone with a working hand to try and twist it back first before ordering a new one (thus saving ÂŁ100 easily) because **** it, money saving!
 
#16 ·
bit more work done today, got the rest of the front end off, got the radiator off, which is still watertight and thus, will be re-used! yay more money saving (odly enough the bike still has all it's oil in too despite a casing being blown open and the block a bit too), i even cracked all the header bolts (you guys with baked in header bolts jealous yet?), meaning tomorrow is exhaust and heat shield removal, weekend will be twisting the subframe back and removal of airbox, injectors etc. or as much as I can be arsed with.

looks a bit naked like this now :/


not actually all that bad, just a dent to it really
 
#18 ·
cheers man, i try and overcome these things as best i can, though i had to ask for help on ONE bolt, the bottom radiator bolt since i can't hold both sides of it lol, and fingers crossed she's back to even better than her former glory soon, just need to source a decent engine and get it dropped in :D

that optiglanz was amazing stuff, stank something awful when it's working, but so worth it, i'll be getting the dremel out and polishing them up again properly with the autosol
 
#19 ·
more progress, and aside from some polishing of the new system and bending the subframe back, there's going to be no further progress until the new engine arrives, i feel it would be more beneficial removing the airbox etc and the engine all on the same day, so it's fresh in mine and my helpers head on engine swap day (many pictures will be taken) so as to ensure as few problems as possible. but i digress, i got the exhaust servo out first, and since removing the footpeg, didn't have a brilliant place to locate the optimate plug, so i improvised and ended up here...


and poking out just enough to be useful, but not enough to be all that visible.


so the end can and heat sheilding, which i hear is totally unnecessary, especially on a track tool, as you can see, the twisting is a little more obvious



then it was the task of header removal, one or two bolts stayed in the head with the nuts coming straight off, some bolts came out the head with the nuts stuck on, either way they all came out easy enough though i'm sure the arrow headers going in will be fun (thank god for the guide I found that is both informative and hilarious).



so as i say, last bit of progress for now until the engine is sourced, or until my card comes and i start on the fairing/paintwork and the polishing which i may let you all see before it's fitted and starts getting covered in crud and hidden behind a radiator :(
 
#20 ·
I'VE FOUND AN ENGINE!!!!!!! this time next week i'll have picked up a mint engine that is clean as anything, even the casings are in good shape, funnily enough it was protected by no cut r&g frame sliders, just may end up investing....
 
#21 ·
Quite the rebuild mate brilliant job so far enjoyed reading your comments it's almost like being there listening to you speaking your mind keep up the good work & the positive attitude it's contagious
 
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#22 ·
thanks man :D i might be rethinking the pure track focus, since knowing my luck, i'm going to need a nighttime legal spare bike because all i've done this year is crash (having a mint year so far lol, one thing after another lol)

but i have found a nice colourscheme from extremefairings that i like the look of, i can reuse most of the headlight stuff but i need a new front fairing bracket (enter delkevic with a nice cheap enough pattern part) i'm still going to do the engine mods i was after, i've got a new subframe on the way which will be going a nice powdercoated black.

i'm halfway through polishing up the headers but man, it takes so long one handed, even with a damn dremel, the new end can should be here tomorrow though fingers crossed :D
 
#23 · (Edited)
ok so not much actual progress, but I have received some new bits, first was the epic trip to get a new engine...



its amazing what you see lol...including the odd nice car


there were plenty more but couldn't get any decent pictures so only this one made the cut, however i do now possess this...



it's cleaner than my current engine, im just waiting on pair blanking plates then i can look at dropping it in.

my plans regarding the fairings change more than my ex's moods, thanks to a mate who lives in the land of haggis and heroin, i was put onto a full set of OEM fairings (minus the mudguard) with all the road needed bits, lights etc. for just ÂŁ350 in near perfect condition, so i took the plunge, got more fairings than i can shake a stick at right now...
 
#24 ·












so now i have spare lights, spare tail fender, spare indicators and a spare rear shock, all of which will be sold, but i need a blue mudguard, i've seen a metallic blue one on ebay, but i don't know if the colour would be the same? its from a 2011 model and looks the same on screen but if anyone can confirm then that'd be ace :D

it's not the colours i wanted, but its better than aftermarket fitment and resale value-wise so im not going to complain since it doesnt look too bad anyways.

hopefully i'll be popping the engine in soon and we can get her back on the road, I can't quite grip anything yet, nbut i have had one titanium rod removed,my hand looks so beautiful
 
#25 ·
ok so finally, some real progress again! I've been selling some bits so getting some pennies back, anyone who wants the engine can have it, ÂŁ200 collected, all is fine on it apart from that bottom end hole, but anyways. start off getting the airbox and injectors off, for all you people moaning about how hard it is and whatnot, SHAME ON YOU, i have one hand and found it easy and moderately fun (i think im a masochist) so i ended up here...



now rather than unplug the whole wiring harness and have to mess about with ALL THAT **** i figured leave it floating in place and just drop the engine, what can go wrong yeah? so that worked pretty good.

now for the hard part, since im a cripple, i got two helpers do the the heavy lifting, after undoing the rear engine mounts, using some 15mm copper pipe we braced the front, and using a paddock stand raised up on wood for extra height to slide the engine out (after the helpers lift the engine off the wooden block, they have enough room to slide it out, giving us two engines, sitting pretty.





so now i have swapped over the bits that are on the engine to the new one, tomorrow the new engine will go in.



this progress from the previous post to here took about 5 hours, this is my first ever transplant, mostly done on my own, with the helpers only doing the heavy lifting, so im pretty happy with the progress, now i know where everything goes etc. putting it back together should be faster i hope, i will update when the new one is in :) blanking plates for the pair system are going in, and i'll be sorting the servo blank circuit too, though i may need to get some new header studs, a few are stuck in the old engine atm....
 
#26 ·
so finally, managed to get some hours set aside to make a dent in this and get new things done, i had actually had a go at fitting the new engine...but the bolt that acts as a spacer and a frame bolt decided that having both of it's tabs snapped and fouling the thread would be fun, however, a grinding stone on a dremel and an easyout soon saw that bastard off....


because the thread on the bolt was damaged, during removal i figured it would have messed up the thread inside the frame slightly, and i was right, so with the new bolt, i threaded from the other side to re-cut the thread and remove any of the old remnants


which worked pretty damn well and now the bolt is snug as a bug and the engine is now in



i had seen a guide about for fitting the notoriously difficult arrow headers, however already 6 hours in and not wanting to have a break i powered on and sussed it fairly sharpish, i won't claim intelligence because i wouldn't have stuffed it otherwise :D so now i have the headers on and secure and the injectors and the majority of the wiring is back in and sorted too.




so now it's a case of finish the airbox and radiator, gut the intake and refit, sort the fairing, get the subby powdercoated and slapped on, fit the end can, get it dyno'd and do the flapper delete, easy enough, though underneath the tank are two plugs, both white, but the plugs that go into them, one is black, one is brown, and i can't for the life of me remember which one plugs in where...
 
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