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Here's what I had to start off with. A 2003 CBR600RR, approximately 8700 miles on the clock and pretty much stock, apart from the odd sticker, some Motrax frame sliders and an R&G tail tidy. One of the first things I did was an oil change (Motul 5100 10W/40, K&N) and I had to get that front tyre changed as it was, to coin that infamous phrase, "barely legal". I got a Dunlop Qualifier, to match the rear tyre, which was pretty much brand new.

The first mods that I went for were crash protectors (R&G fork protectors and rear axle sliders, along with some over sized cotton reels) and a tinted double bubble screen. Shortly after, I went for some elite vinyl designs reflective rim tape and a black Pro-Bolt kit.

That summer, I then began to concentrate on some more performance based mods. I fitted:
- A GPR Tiburon Evolution slip on
- RK GB520GXW chain
- Supersprox stealth 520 pitch rear sprocket (44 teeth)
- Renthal 520 pitch front sprocket (15 teeth)
- BMC street air filter

Around this time, I also put on an HRC tank pad/fuel cap cover and some Stompgrip tank pads.

I then had my first problem with the bike: my off-side fork seal failed. I put the bike into a local garage for a quick check over whilst they changed the fork seals (not entirely confident of doing this myself). They also replaced the steering head bearings, whilst they were at it. They were a bit notchy and this had been noted on a previous MOT on the bike. I think a previous owner must have been a bit of a wheelie addict!

 

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I decided that the bike looked a lot cleaner without the passenger pegs and, because I don't often carry passengers, I decided to remove them. Around this time, I also bought and fitted a black belly pan from an '04 bike. I thought this looked a lot cleaner than the silver lowers that came stock on the '03; kind of keeping it to the red/black theme.

Towards the end of last year, I decided to go for some more "bling" and had my rear sets and passenger pegs powder coated flat black. I had also been admiring Tripage's work for some time on the site and decided to go for some passenger peg turn signals and had my gauge cluster LEDs changed to match the red/black theme. I also fitted some Motrax D light flush mount front turn signals at the same time.

Over the Winter, I fitted some real carbon fibre engine and clutch covers (sourced from a carbon manufacturer in Ukraine) and scooped up some brand new CRG levers from a dude who was getting rid of his spare track bike parts.

That didn't take too long to do and the winter brought horrendous amounts of snow. Because I was unable to ride, I had to give the bike some loving. I decided to improve the braking efficiency and fitted Goodridge braided "carboline" brake lines all round. I went for the "race" front line option (2 separate lines from the master cylinder). I also then decided to overhaul my callipers; splitting them, giving them a good clean and fitting new seals. Because of the gearing change that I had completed earlier in the year, I decided to fix my inaccurate speedo reading by fitting a Speedo DRD. I also then picked up a PCIII USB; with a view to picking up some add on goodies for it and eventually getting a full custom map. The eagle eyed of you may also notice the Lost Caws frame plugs and HRC reservoir sock!

Here's a video, and a picture, showing my Tripage LED Passenger pegs and gauge cluster colour change:

 

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As this year's new riding season approached, along with the yearly MOT test, I continued working on the brakes by fitting Galfer pads & Galfer wavy discs all round. I also did the HRC reservoir delete using Tygon tubing sourced from Kurveygirl. Then there was a bit of pre season TLC in the form of a quick oil change; this time to Motul 300V (10W/40), again with a K&N filter.

Prior to my MOT date, I looked up the UK motorcycle MOT requirements and noticed that my bike didn't comply as it didn't have a red rear reflector. I fabricated a new number plate backing plate from sheet aluminium. I left a small lip under the number plate so that I could stick on a small red reflector. I then painted the backing plate using black stone chip resistant paint and stuck my number plate on to it using extra strong double sided tape.

A couple of months ago, I booked my first track day and got the bike all track prepared by removing some non essential parts and fitting one of Brian's MOTY Design lightweight batteries (highly recommended)!

 

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Here are some action shots from the day (excuse the very poor form!)

I'd highly recommend taking the plunge on a track day, for any of you who have been curious. You have so much more grip at your disposal that it honestly is mind boggling. You can brake ridiculously hard and turn with much more confidence than on the road. It really helped my riding but, unfortunately, I'm now hooked and track days are a tad expensive.

I also came away craving a mod: an HRC quick turn throttle. The stock throttle cam had my right arm aching after a full day at the track! My only other top tip would be to get mirror block off plates so you can remove your mirrors for track use. They really are an unwanted distraction for track riding.

The season's coming to a close here at the moment but I hope to get up to the track once every couple of months next season.

 

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Again, following the theme from last year, towards the end of the season I have gone a bit mod crazy. I decided to buy some goodies and parts for an '09 front end conversion:
- HRC quick action throttle (as mentioned above; a must for track days)
- Dynojet Ignition Module
- Dynojet Linear Travel Quickshifter
- Complete '09 front end (including wheel)
- New front Goodridge carboline brake lines (to fit the new front end and radial master cylinder)

 

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Here are some pics from the work, as I went along, on the '09 front end conversion. To do this on an '03-'04 bike, you will need the forks, triples, clip ons, front wheel, spacers and axle. You will also need new front brake lines (to fit an '07+ 600rr).

 

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Here's a photo from after the fork conversion...

 

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…And a summary of the main challenges faced during the conversion:

It was a bitch to get the brake lines into the m/c in a way where they didn't foul the air tube covers on full lock or block off access for the brake light switch wiring. A bit of fiddling and perseverance saw that one off though. Not a major issue.

The lower portion of the air duct covers also need a bit of trimming. Upside down forks will rub the stock '03-'04 air duct covers. If you have an '05-'06 bike then the air ducts are different and you shouldn't have this problem. Having said that, I don't think there's any difference (other than colour) in the 600rr forks from '05 onwards. In that case, I think this mod is more likely to be done by '03-'04 owners anyway.

The HESD mounting tab on the top yoke fouls the tank cover. Cutting into the tank cover wouldn't work as the HESD mounting tab would then foul the left hand bolt which holds the tank cover on at the front. I had to dremel the mounting tab off and painted it using some black stone chip resistant spray paint. It blended extremely well but you can still tell it's been a ghetto solution to the problem.

The other option to cure this problem is to use an '05-'06 top yoke. I think, in the long run, I will probably do this, but will go for an aftermarket top yoke.

Adjusting the throttle cables for the HRC quick action throttle was a complete PITA:

 

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The radial brake m/c also needs a bit of adjustment, so it doesn't foul the fairing stay or gauge cluster. Again, with a bit of perseverance and some patience, you can see this one off:

The quickshifter and ignition module were relatively straight forward mods to do. The quick shifter comes stock with a 60ms kill time. After seeing some users recommending a 45ms kill time, I tried 50ms to begin with. After a couple of rides, I decided to go up to 55ms for smooth gear changes. 50ms was a little too rough IMO.

 

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Well, here's how she currently sits:

My bike's come a long way since I bought it, but there are still a few mods on the cards:
- Ohlins rear shock
- New mount kit for my Ohlins steering damper (the '03-'04 one doesn't fit on an '05+ top yoke)
- Aftermarket top yoke (to replace my ghetto solution to the HESD mount problem)
- Powdercoated swingarm (flat black)
- Track fairings
- Custom map & suspension setup

Depending on how things go, I might also get round to some of the other mods on my dream wish list:
- Galespeed Type-R forged aluminium wheels
- STM slipper clutch
- Gilles AS31GT rearsets
- Gilles chain adjusters
- Brembo RCS front master

 

[crash277]

nice write up!! and real nice job on the bike!! looks great!

 

[zhjiln]

booo blasphemy... suck it sunzoomspark

see you in the ban thread.

PS.
that GPR is the bee's knees

 

[zhjiln]

by the way, did GPR include a db killer for your tiburon exhaust.

i just had to purchase a $28 db killer for my thunder deeptone because i got tired of my ears bleeding.

 

[Sun-Zoom-Spark]

nice write up!! and real nice job on the bike!! looks great!

Thanks man. I thought about upgrading to either a newer 600RR or an 848 earlier this year but decided to go down the track days/excessive modification of my existing bike route.

booo blasphemy... suck it sunzoomspark

see you in the ban thread.

PS.
that GPR is the bee's knees

Blasphemy?

by the way, did GPR include a db killer for your tiburon exhaust.

i just had to purchase a $28 db killer for my thunder deeptone because i got tired of my ears bleeding.

Yep, the exhaust came with a db killer. It's never been in though. The exhaust isn't excessively loud without it anyway, plus you have to remove the end can to get the db killer in, which is a pita.

That sucks about your exhaust. I'm pretty sure the Thunder Deep Tone is the expensive, top of the range GPR so I'm surprised it didn't come with a db killer? Are you sure it wasn't just missing from your package?

 

[sincalirider]

She looks great so far, good job.

 

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Upgrades!

Last night, I finished off putting the bike back together with my new shock, powder coated swing arm and a new mount for my steering damper:

Just have the chain to sort out now...

Not sure how well the damper is mounted tbh so I'll need to try that out. If need be, I may have to get an '05-'06 top yoke. Having said that, I don't think there's a huge difference (between '05-'06 and '07+) in the shape of the yoke around where the damper mount sits. The HESD holes don't interfere and I have removed the mounting tab on the yoke anyway. Road test on Sunday I think!

 

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Shame the roads are in such a state around here...******* farmers!

 

[Book79]

who did your flat black powdercoating, what is the pait code?

 

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who did your flat black powdercoating, what is the pait code?

Sorry for the tardy response. It was a local business called Coatech, in Carnoustie. I didn't get a paint code; just asked for flat black. They did the rear sets, passenger pegs and swing arm for me and the paint match is excellent for the bike.

If you're in the US then I'd highly recommend Tripage if you're looking for powder coating. He'll keep you right. I would've gone to him for my powder coating if shipping wasn't so prohibitively expensive. I had a bit of a nightmare with the swingarm because I had to do all the prep myself and failed in a couple of areas, creating extra work for myself...