OveRReV's 03-04 600RR rebuild thread

[OveRReV]

well i finally had the guts to start a build thread here, i know it's nothing special as it's just an old 03-04 600RR but anyway here's the story.

last Dec i crashed my bike in a lowside when i overtook a rider on the outside of turn3 at my favorite track which is known as "the corkscrew" which is inspired by the Laguna Seca circuit. the damage would have been minimal if it weren't for the Vortex frame sliders breaking off but it hit something hard when it slid off the track so can't blame all of it on the frame slider. it also took out my swingarm spool so my swingarm is facked so now i'm in the hunt for a new one.

also the engine is consuming oil, as i roll off the throttle the riders behind me can clearly see smoke coming out of my exhaust outlet so engine needs to be rebuilt too, i already bought piston rings, valve stem seals, head gasket & some other stuff for it, should be here next month as shipping by sea cargo is cheaper but so damn slow to arrive.

now i have decided to convert my bike from street/track to track/race only as i plan to race in the 600 superstock class next year so i'm going to prep my bike this year in advance, hopefully by Nov or Dec the bike will be completed in time for it's shakedown runs at the track.

for track bodywork i'm leaning towards Optimal if they make one for the 03-04 models, if not then i have to look for somewhere else. i already have spare wheels to mount my rain tires on thanks to strgt, a spare Power One V front tire which i will use for practice when i get a matching rear tire for it, an HRC secondary rad along with silicone hoses (and a spare rad) so thanks to Robot Ninja Pilot for a sweet deal.

i already have a host of mods done to my bike & i shall upload pics later once i get this rebuild up & running, when the engine parts arrive i'll start the disassembly of the bike. i just hope the bores are still in good condition, can't afford a new motor or a replate at the moment.

[TribalCBR06]

I didn't know you crashed Pare. good luck with the build, i'll definitely be checkin in to see how far you get.

<-- San Miguel Beer

[FlipDiver79]

Subscribed. Keep us posted bossing...

[iLLsYn'd]

I wanna race! ahh I wish one day! GL on build bro!

[OveRReV]

thanks for the encouragement, now a rebuild thread is worthless without pics so here's the lowdown on what i have at the moment.


WP steering damper


HEL brake line kit


Euro Racing riser plate & shifter kit






WP 4618 racing shock


Polini Evolution Titanium slip-on (my first exhaust mod)


Ohlins 0.90 kg/mm fork springs


modified compression & rebound pistons & shim stack with Bitubo shims


Bitubo shims set

[OveRReV]

Brembo 19RCS MC




Akrapovic Evolution full system


Power Commander III USB with downloaded map


AFAM 15/47 sprockets with DID ERV3 520 racing chain


Zero Gravity double bubble windscreen


HRC auxilliary radiator with the spare OEM rad

i will post up more pics later, i'll show what's left of the vortex frame sliders & the damage done to my swinagrm, this bike is getting a major makeover.

[slim8]

You have spent your money on some very nice parts.

[OveRReV]

Originally Posted by slim8

You have spent your money on some very nice parts.

money is hard to come by these days so i should only buy things that really make a difference, i didn't buy this all at once though it took me a lot of work & saving before i bought the rear shock, full system, PCIII, Brembo & other stuff in there.

now i'm in the process of rebuilding the engine & i just spent $300 on head gasket, piston rings, valve stem seals, steering head bearings, slider & guide bushings for the fork & a couple of days ago i also got a very nice front wheel complete with rotors for $200 so the completes my spare wheel set & this is what i'll be using it for.


Michelin Pilot Race rain tires 12/60-17 & 18/67-17

they're practically brand new, i found them at a local japanese used parts dealer for a sweet price of $50, that takes care of my wet tires.

i'll post more pics of what i have acquired for my bike, hopefully this guy who used to race his 03-04 600RR has most of his stuff lying around, i'm interested in getting his track bodywork from him.

[slim8]

Originally Posted by OveRReV

money is hard to come by these days so i should only buy things that really make a difference, i didn't buy this all at once though it took me a lot of work & saving before i bought the rear shock, full system, PCIII, Brembo & other stuff in there.

I hear ya man it has taken me a year to get some decent parts.

[djentangle]

looking good so far

[OveRReV]

Originally Posted by djentangle

looking good so far

not from my point of view, i haven't touched the bike yet & just thinking about disassembling it puts shivers down my spine, i just hope the engine holds up together long enough to finish the season when i'm done with the rebuild. LOL

[michaelwood]

Originally Posted by OveRReV

not from my point of view, i haven't touched the bike yet & just thinking about disassembling it puts shivers down my spine, i just hope the engine holds up together long enough to finish the season when i'm done with the rebuild. LOL

It should, just inspect everything, might have to go with 1mm overbore pistons if the bore is scuffed up.

Also are you gonna get all balls tapered steering head bearings? They hold up better in a crash. What tools are you gonna get to put them in? You can use a dremel and carefully cut the old bearing race off the stem but it's best to get the tool to put the new bearing race on. Also maybe upgrade to an 05-06 swing arm then get axle block sliders to save the swingarm in a crash.

Good luck man, I'm also looking to race my 2004, and will build it up soon

[OveRReV]

Originally Posted by michaelwood

It should, just inspect everything, might have to go with 1mm overbore pistons if the bore is scuffed up.

Also are you gonna get all balls tapered steering head bearings? They hold up better in a crash. What tools are you gonna get to put them in? You can use a dremel and carefully cut the old bearing race off the stem but it's best to get the tool to put the new bearing race on. Also maybe upgrade to an 05-06 swing arm then get axle block sliders to save the swingarm in a crash.

Good luck man, I'm also looking to race my 2004, and will build it up soon

that is what i'm afraid of, a scuffed bore, going to cost me an arm & a leg to send off my case to be replated there, i just hope it's the rings or valve stem seal that's the culprit.

i just bought the OEM steering head bearings, had i known there was a tapered version available i would've got them instead, got link for that?

i'm racing under superstock rules so i need to get the right year swingarm for my bike, too bad the 05-06 swingarms have a nicer look & slightly lighter but rules are rules.

finally found a set of race bodywork locally, got it for $250 from a retired racer who used to race an 03-04 600RR, he had a lot of good stuff on his bike including an STM slipper clutch, too bad somebody already beat me to it & all he has left a a yoyodyne slipper clutch, i'm going to have to track down that STM slipper i may need it for future use.

[michaelwood]

As requested, here's a set of tapered roller bearings on ebay:
http://cgi.ebay.com/ebaymotors/ALL-B...-/120663131513

Got a set myself, gotta get a few tools to put them on though.

[OveRReV]

Originally Posted by michaelwood

As requested, here's a set of tapered roller bearings on ebay:
http://cgi.ebay.com/ebaymotors/ALL-B...-/120663131513

Got a set myself, gotta get a few tools to put them on though.

oh damn it, i paid $23 for an OEM steering head bearing, had i known this i would have gotten it instead.

i want to kick myself now.

[OveRReV]

finally scored a set of race fairings from a retired 600RR supersport racer, got the whole thing for $250, all it needs is some drilling & a new paint scheme, now which bike do i have to copy here? hmmmmmmm..... :D

[michaelwood]

NICE! looks like you scored some carbon fiber! the paint doesn't look bad either, I guess you just want to make the color scheme your own?

Are those side pieces carbon or just a CF sheet over the original ones. I've been looking for CF ones for a while. You have some very sexy parts there.

[michaelwood]

Originally Posted by infinate719

Are those side pieces carbon or just a CF sheet over the original ones. I've been looking for CF ones for a while. You have some very sexy parts there.

Yeah they look like Carbon Fiber to me, but they're not close enough to the camera to tell for sure. I've seen them on ebay before. Not sure if you'll have any luck.

Beautiful parts overrev,

[OveRReV]

thanks everyone, yes the side panels & hugger are CF, he threw those in as he has no more use for them.

once i get some bikes off the shop i can start tearing down the motor, hope it isn't a scuffed bore or i'm facked.

[scrappydog19]

looks like your building a nice parts cache! i wish i could find a set of race plastics for my '03 for $250. i'd also like to pick up a set of those riser plates you got, but can't seem to find any stateside.

[OveRReV]

Originally Posted by scrappydog19

looks like your building a nice parts cache! i wish i could find a set of race plastics for my '03 for $250. i'd also like to pick up a set of those riser plates you got, but can't seem to find any stateside.

OPP Racing has them, here's the link.

http://www.oppracing.com/product_dis...br600rr-03-06/

if you do get them though you need to fab a small spacer for the shifter pivot, Euro Racing overlooked this small problem of machining the shaft a bit short, when you tighten the bolt it locks up the lever. see this thread for details.

http://www.600rr.net/vb/showthread.php?t=127341

for race fairing i was looking into this before i scored mine.

http://motofairings.com/products_det...cto=71&marca=5

$290 + shipping, let me know if you bought them, i want to see how it fits yours.

[scrappydog19]

Originally Posted by OveRReV

OPP Racing has them, here's the link.

http://www.oppracing.com/product_dis...br600rr-03-06/

if you do get them though you need to fab a small spacer for the shifter pivot, Euro Racing overlooked this small problem of machining the shaft a bit short, when you tighten the bolt it locks up the lever. see this thread for details.

http://www.600rr.net/vb/showthread.php?t=127341

for race fairing i was looking into this before i scored mine.

http://motofairings.com/products_det...cto=71&marca=5

$290 + shipping, let me know if you bought them, i want to see how it fits yours.

thanks for the links ReV! i'll definitely be checking them out when i get a few minutes at work.

[OveRReV]

my front wheel just arrived at my friend's house, it came from an 05-06 & it's in perfect condition, the rotors are also included in the deal, not bad for $205 shipped.



good things come to those who wait.

[OveRReV]

got more stuff dropped off at my friend's place at WA.

[OveRReV]

still waiting for my swingarm to arrive, i haven't ordered spare DID ERV3 rivet links & a folding rear brake pedal yet.

[elements018]

nice build so far man, keep up the good work

[SLAPS808]

interesting...

nice project pare! its about time you made a thread like this.

[OveRReV]

thanks pare! yeah it's probably a good time to start a project page so all the guys here can see how cheap i am. LOL

anyway my new swingarm just got delivered to my friend's house, the last 3 pics showing the whole swingarm from both sides didn't load so this is the best i could get at the moment.

[SLAPS808]

maybe i missed it...whats wrong with your original swingarm?