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03-06 RR Modifications 2003, 2004, 2005 and 2006 Modifications

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Old 01-29-2012, 12:24 AM   #1
Greg-NWO
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06 Track Bike Build

So I picked up an 06 600RR for $600 with the idea of making it into a track bike by the start of the riding season. I'm going to try and document the build in this thread.

Here's what I started with.... no engine as you can see and not much bodywork. The engine was obviously an issue but the bodywork didn't matter since I will be buying race bodywork for the bike anyway.



Once I got it home and removed a few things I had it to this stage. It was at this point I really started going through the whole bike looking for things I might have missed on my initial inspection.

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Old 01-29-2012, 12:28 AM   #2
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Doh, first big find. Rear rim is trashed.



Found one on ebay for $100 so not too bad. Need to figure out if I can use the tires for a track day or two. I think they should be ok... most of the wear is in the center and the outside of the tread is fairly new.

Next thing I found was the footpeg bracket was cracked when the previous owner layed it down.



Shouldn't be a big deal to find a replacement.
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Old 01-29-2012, 12:40 AM   #3
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One of the bonuses of this bike was an uncracked headlight. I'll be able to recoup some money by selling it off.




I spent the day today tearing the rest of the bike down and worked on cleaning everything and inspecting everything. The last thing the p.o. said to me was he had "dismantled everything just for fun" so that's why a total teardown is necessary :)

I also found a motor today! It's an 06 motor that has been compression tested from a wrecker. The valve cover is cracked but I have a replacement from the spare parts I got with this bike so it should work out perfectly.

Also on order is a Scorpion exhaust slip-on, throttle cables, rear brake lever, Clymer manual, safety wire pliers and swingarm spools/sliders.

Will probably be a week or so before the engine arrives but that is the thing on the install list. After the engine is in I will get the swingarm back on and install the wheels etc. etc.

First parcel arrived yesterday... nice new set of levers. Nothing fancy but they will do.

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Old 01-29-2012, 12:47 AM   #4
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Here's where things were left at today:

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Old 01-29-2012, 01:01 AM   #5
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Good luck with the project, it will be great to see it come back to life!
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Old 01-29-2012, 01:16 AM   #6
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I need to find a project like this. Good work with the rebuild!
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Old 01-29-2012, 09:42 AM   #7
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Good luck on the build. I found a project similar to this last fall but with a motor. Try not to keep track of costs because they will get higher than you expect.
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Old 01-29-2012, 05:48 PM   #8
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I give you full props for this.... By the time you spent all the $$$ to put it back on asphalt you probably would have been close to buying one road ready but at least your building it your way!! $600 for the frame etc is worth it so keep us posted and good luck.
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Old 01-29-2012, 09:24 PM   #9
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Well I'm at $1772 at this point. I still need race bodywork, a chain and sprocket set and a few other odds and ends I'm sure I'll discover - so another $1000 give or take.

$2700 for a race ready bike doesn't seem too shabby?
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Old 01-29-2012, 10:11 PM   #10
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Hell no it doesn't! Like I said, I need to find one of these myself.
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Old 01-29-2012, 10:18 PM   #11
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Did u need a new foot peg? I have two oem ones
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Old 01-29-2012, 11:21 PM   #12
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Trying to decide if I am going to just get rear sets or keep the stock pegs. Will let you know, thanks!
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Old 01-30-2012, 07:58 PM   #13
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No new pics but my "new to me" motor is on it's way and I worked out a deal with another dot net member for some race bodywork.

Now I just have to play the waiting game while everything is in the mail. Motor is supposed to be delivered the 7th.

I inspected my swingarm yesterday and found the oil seals on the swingarm are pretty ragged so my local Honda dealership is checking into a seal and bearing kit for me. Also got them to order a front axle pinch bolt since one of the bolts got ground down a fair bit when the PO laid the bike down.

One question I have that hopefully someone can answer.... does the stock wiring harness have a quick disconnect between the main harness and the subframe harness on an 06? From what I've read it's supposed to but my harness definitely does not. I'm wondering if it's an aftermarket harness because there is a sticker on it that says made in China with a bar code. Any thoughts?
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Old 01-31-2012, 02:37 PM   #14
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Quote:
Originally Posted by Greg-NWO View Post
No new pics but my "new to me" motor is on it's way and I worked out a deal with another dot net member for some race bodywork.

Now I just have to play the waiting game while everything is in the mail. Motor is supposed to be delivered the 7th.

I inspected my swingarm yesterday and found the oil seals on the swingarm are pretty ragged so my local Honda dealership is checking into a seal and bearing kit for me. Also got them to order a front axle pinch bolt since one of the bolts got ground down a fair bit when the PO laid the bike down.

One question I have that hopefully someone can answer.... does the stock wiring harness have a quick disconnect between the main harness and the subframe harness on an 06? From what I've read it's supposed to but my harness definitely does not. I'm wondering if it's an aftermarket harness because there is a sticker on it that says made in China with a bar code. Any thoughts?
My harness did not have a disconnect that I can remember. I would have kept it anyway because my Bazzaz gets its power from the rear tail light wire.
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Old 01-31-2012, 02:39 PM   #15
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Definitely send the forks off to get them checked for straightness. I thought mine were good and found out this winter when getting my ohlins internals that I was riding with them slightly tweaked even though they looked straight.
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Old 02-02-2012, 07:00 PM   #16
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One of the most important parts of the build arrived today :)



Bodywork is scheduled to arrive Monday and the engine on Tuesday. Hopefully lots of other bits next week as well.
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Old 02-03-2012, 09:11 PM   #17
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Just realized this thread should probably be in the builds section of the forum so if a mod wants to move it be my guest!

Got a delivery card in the mail today, not sure which part has shown up but I will go pick it up tomorrow and report back. Hopefully it's my exhaust :)
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Old 02-04-2012, 06:09 PM   #18
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I'm in the process of doing the exact same thing myself. Keep us posted on how it goes
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Old 02-05-2012, 03:09 PM   #19
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Well the parcel wasn't the exhaust... just these swingarm spools. After reading a bit I think I will get a set of the sliders that go through the axle as well.

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Old 02-06-2012, 12:17 AM   #20
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good looking build so far...can't wait to see the finished results.
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Old 02-06-2012, 01:03 AM   #21
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Props on the build! Keep us posted!
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Old 02-06-2012, 09:32 PM   #22
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Ok, so an exciting day in the shipping/receiving dept. First I had a massive box waiting for me when I got home. Thanks to Carbon_600 for a beautiful set of race bodywork!



Next I had a delivery at the post office.... I know what this is :)



$199 and it's brand new, pretty good deal. The PO decided he wanted to try and take the baffles out of the stock muffler and took a grinder to the can and destroyed it so that's why I needed a replacement.



Oooooo... Pretty haha




Tomorrow I am going to go pick up my engine just across the border at International Falls. Then I will finally be able to start putting things back together!
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Old 02-07-2012, 08:40 PM   #23
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Got my motor!



Here's the damage to the valve cover. I've swapped it out already... no issues. The clutch cover is scraped up a bit so I may get a hardened racing cover to replace it with just to be safe.

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Old 02-08-2012, 09:58 PM   #24
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More waiting on parts.... ordered some Woodcraft frame sliders from bluestreakracing.ca - should be in next week then I can finish bolting in the engine. Swingarm bearings and seals should probably be in tomorrow so I can work on that.

Picked up some insulation so I can finish insulating my garage. Will heat up much better when that is done :)
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Old 02-08-2012, 10:02 PM   #25
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Nice! Can't wait to see when it's done! Glad you were pleased with the fairing. Take some pictures for me of how the harness was run :P lol.
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Old 02-16-2012, 08:24 AM   #26
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Looking good man, I'm new to bikes and had trouble installing an L.E.D kit on my bike...let alone putting the entire thing together!
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Old 02-16-2012, 08:50 AM   #27
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looking good. Love projects... so much fun!

Could maybe purchase a small table to put the frame on while you build it up and so on... might be easier than working on the floor.
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Old 02-16-2012, 02:31 PM   #28
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Thanks! It's actually on a small home-made motorcycle table.... about 18" off the ground or so.

Well I have gotten some more work done. Had some more parts show up I was waiting on.

First a rear rim that is in perfect shape.... much better!



Next up what I really needed... a nice new set of Woodcraft frame sliders! Very nice quality, I'm very impressed.



The frame sliders let me mount the motor fully in the frame and torque it down.



My swingarm bearings and seals should be in shorty and then I will start putting the rear end on.
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Old 02-16-2012, 11:08 PM   #29
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Bearings and seals came in today!



Got those changed out and mounted the swingarm and shock. Next I think I'll get the wheels put back on with a set of takeoffs from a friend. (found out the tires the bike came with were all weather cracked... didn't notice at first)

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Old 02-16-2012, 11:21 PM   #30
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Damn man! Lookin like a solid build! Estimated cost u think for the whole project?
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