600rr 07 clubsport racebike build

[BoB]

I have been working on this project for a while now , collecting bits off ebay when they come up cheap and hopefully it will be ready for my 1st race meet with st george mc club in November . I had done most things with the cbr but one that i hadnt done was a complete engine rebuild so i was keen to see how it was put together . I bought a very cheap bike from the auction that needed a new motor as the one in it had the engine casing damaged where the oil pressure line is . I bought a spare crankcase from the states and started the strip down.

http://imageshack.us/a/img196/3485/20120821231.jpg


top cover removed showing cams
http://imageshack.us/a/img825/2181/20120821235.jpg

camshafts removed
http://imageshack.us/a/img839/7669/20120821251.jpg

Rhs engine showing clutch and starter clutch removed
http://imageshack.us/a/img692/4372/20120821256.jpg

Cylinder head removed
http://imageshack.us/a/img690/5238/20120821253.jpg

Underneath the motor , when the sumps removed showing the oil pump. Having the motor attatched to an engine stand really helps when doing any work on the motor.
http://imageshack.us/a/img837/9189/20120821264.jpg

Oil pump removed .
http://imageshack.us/a/img24/636/20120821270.jpg

Lower casing removed.
http://imageshack.us/a/img96/7824/20120822272.jpg

Crank and gears.
http://imageshack.us/a/img27/5109/20120822273.jpg

Now to assemble the bits into the newish casings. Cleaned up the bores with flexhone.
http://imageshack.us/a/img21/2687/20121015372.jpg

Pistons fitted with new rings.
http://imageshack.us/a/img542/853/20121030399.jpg

New bearings for the crank and conrods.
http://imageshack.us/a/img819/429/20121031406.jpg

Casings back together .
http://imageshack.us/a/img526/7951/20130105557.jpg


I didn't remove the valves or do anything else to the head , apart from a new head gasket and just checked the clearances when i put the cams back in , all were ok .
http://imageshack.us/a/img13/8342/20130402777.jpg

Frame has been blasted cleaned and powdercoated to make it look new again as the previous owner had painted bits of it a terrible orange colour .
http://imageshack.us/a/img705/528/20130402774.jpg

Nice and easy does it . Good to have a few axle stands to hold everything when lowering the frame onto the motor.
http://imageshack.us/a/img822/4675/20130529954.jpg

Had to fit the new throttle cables before the airbox goes on , new motion pro set up with interchangeable throttle discs . Fitting the airbox has to be the worst job so far , still havent found the best way yet to make it easy. Wiring harness and swing arm fitted .
http://imageshack.us/a/img560/3015/20130529959.jpg

New Akrapovic headers .
http://imageshack.us/a/img203/3867/20130529966.jpg

Subframe and exhaust finished off . Started to fit the new cooling hoses.
http://imageshack.us/a/img580/6100/20130611972.jpg

Got a few more hours on the biketoday. Radiator fitted , air intake and dash , filled with some wet stuff , no leaks

checked the oil ... connected battery and gave her a spark of life ...... She is alive...

Runs smooth once the fuel got into her .
http://imageshack.us/a/img811/1217/20130612980.jpg

http://imageshack.us/a/img189/4967/20130612981.jpg

Fitted up the wheel .. need some more rubber and put the calipers on and bled the new brembo. Its a tight fit getting the master cylinder , kill switch and the throttle on the bar.
http://imageshack.us/a/img209/1897/20130612983.jpg

Now to do some tidying up and finishing off some bits and pieces ... might even get to come out to play on the 27th. Not sure what the best way to go with the power commander . I have a pc5 and an auto tune for it with a race air filter , maybe put the standard air filter in for now and take it easy without the pc5?

[Little Mick]

looking great Bob!

[Mstevo]

I'm about to start something similar myself and intend taking lots of pictures too, it's a great feeling of achievement when you build, race and win on something you've created yourself

[BoB]

I'm about to start something similar myself and intend taking lots of pictures too, it's a great feeling of achievement when you build, race and win on something you've created yourself

I took plenty of pics when stripping down the motor , to help remember how things went together . As long as i overtake at least a couple in a race meet and just get out there and have a go to see how big the buzz is. I really enjoy the building, so much easier and less space than working on cars.

[Marshy]

Awesome, awesome, awesome!!! Love your work!! :hail:

[senator8]

Great write up Rob.
Looking forward to seeing you at your first race meeting :)

[Mstevo]

I took plenty of pics when stripping down the motor , to help remember how things went together . As long as i overtake at least a couple in a race meet and just get out there and have a go to see how big the buzz is. I really enjoy the building, so much easier and less space than working on cars.

Yep that can be a problem if you waiting a long time for parts etc
my technique is to group all parts and bolts from each layer you take off and lay on a big piece of cardboard(1.2 x 1.2m) in a circle with texter labels in a flow chart style

[BoB]

Yep that can be a problem if you waiting a long time for parts etc
my technique is to group all parts and bolts from each layer you take off and lay on a big piece of cardboard(1.2 x 1.2m) in a circle with texter labels in a flow chart style

I used a piece of cardboard and punctured it with the bolts so i got them in the right order as some of them were different sizes . Although i didn't use the same bolts in the rebuild (used new ones) it helped me work out which went where.

As I had to stip the motor to find the original bearing sizes off the crank and using a new crankcase ment i had to work out new bearing sizes and then wait for them to come from the states , and yes i did forget some things but using pics and the manual helped me remember.

[chubb]

Good stuff!! Will definitely be following this

[Negrogrande]

nicely done

[Saturnalian]

Awesome Rob. Can't wait to chase you round on it.
Now how do i wangle a clubsport bike before November....:noidea:

[Saturnalian]

Hey Rob,

Where did you get your RCS from ?

[Baddie]

Matey.
What’s with the OOOBOB engineering Master cylinder bracket…lol

Why didn’t you relocate Kill switch to other side if it helps?

Looking good….let hope all that work doesn’t end up with spray can paint job!!!.
:thumb:

[BoB]

Matey.
What’s with the OOOBOB engineering Master cylinder bracket…lol

Why didn’t you relocate Kill switch to other side if it helps?

Looking good….let hope all that work doesn’t end up with spray can paint job!!!.
:thumb:

Yes i have been thinkinh of putting the kill switch on the other side ..and the bracket for the reservoir is just temp till i fit the fairings and make sure its the right height ..

[BoB]

Hey Rob,

Where did you get your RCS from ?

i take it you mean the brembo brake .. i got it from the states , on the 600rr forum .

[Saturnalian]

i take it you mean the brembo brake .. i got it from the states , on the 600rr forum .


$$$$ ??

[Marshy]

I got mine from solomoto or motomummy. $300 new. But I bet Rob got an awesome deal on a secondhand one online :thumb:

[BoB]

$$$$ ??

It's been that long since I bought it I cannot quite remember the price but I think it was 300 inc posting to sydney and came with reservoir and hose.

[dan]

Nice work mate!