Red - The Build!

[Turbo]

So, I've heard the best thing for recovering after breaking your bones is to buy another bike!
Picked this guy up from an auction today...





Pretty sure the front needs some attention, either that or it loves right handers...




Happily, removing the headlights etc. has already been taken care of by whatever it hit, but closer inspection shows a ding to the front left fork tube.




After checking oil and electrics etc, saw no reason not to boost up the battery and it started first try!




Bit of a scuff on the right hand side. That's clearly written it off, best check the air box for oil...




Ooooh. score! Already has a BMC filter in it.. pretty clean too!




Yep, just a bit of oil made it up but probably enough to make it cough out blue smoke for a while.. best clean it out.




Might as well do the smog block off while I'm in here...




Deffo need to take this god-awful thing off.. cheapest piece of junk I've ever seen!




Stripped! Not bad for a night's work by an invalid! Now to go buy some fast things to put on it...

[Phat3R]

Nice Owen - that's going to help your recovery! Is that a stock shock / spring?

[Turbo]

Thanks Rick! Yes, all bouncy bits are stock at this stage.
Hoping to re-create your Ohlins valved & rebuilt front end tho, as I've heard it's ACE!
Not sure about the back end yet...

[Leezx10r]

Looking great Owen, will be a little monster when finished.

Keep posting the progress of the build mate.

See you at the track soon


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[chubb]

Wana make your bike go faster?? I got cams. I also got a rear Mupo shock. Heheh

Nice pickup. But what's with the pov pack block offs?? Plates cost $20

[Turtle]

Nice little catch for a project man. Similar condition to a Gixxer 6 that I helped a mate rebuild. It was surprisingly fun stripping it down and getting excited about replacing parts.
Good thing about project bikes is you can set your own timeline. Ain't no need to go broke buying everything in one hit.

Keep us updated! I'm keen as chips to get myself a track R6, so eager to learn about more of their potential hidden secrets/flaws.

[dan]

Looks like this will be fun. Can't wait to have a spin

[Mr.Ed]

Good luck with the build and recovery, mate!

My only comment is, WTF is with all that rust on the exhaust?? My bike is parked near the ocean and for a looooooooooooooooong time and I never had anything like that... ever!

[Turbo]

The new parts have arrived!!

[Turbo]

Good luck with the build and recovery, mate!

My only comment is, WTF is with all that rust on the exhaust?? My bike is parked near the ocean and for a looooooooooooooooong time and I never had anything like that... ever!

Thanks mate and YES! That worried me too. It appears to be the cheapest mid-pipe/cat eliminator on the planet and is made from the cheapest 'metal' I've ever seen. Once removed, the headers and rest of the bike are fine tho.

[Turbo]

Looks like this will be fun. Can't wait to have a spin

2nd in line mate!

[Turtle]

Going to look at an 08 and an 09 R6s tomorrow... These bloody threads have infected my brain and all I can think about is turning one into a track beast.
If I end up broke and homeless it's this forums fault.
Least I'll have bikes though.

[Marshy]

Least I'll have bikes though.

Great attitude!! Love it!

[Turbo]

New front end arrived yesterday. Unpacked last night and it's fookin mint!!




It's either been astonishingly well cleaned or it's not done much road time at all....



Forks out and we'll get to work on the re-spring, service and super awesome shim stack!

[Turtle]

Them be some tidy forks.

[Turbo]

A wee bit more progress on the build...

The old and bent front end is now completely off. The new front end was so clean and tidy, it made sense just to swap everything and not be worried about any potential issues.



A good opportunity to get in to the spark plugs and swap them out...



Can't remember which ones I changed tho...



New intake and fairing stay are now fitted. Managed to find an intake with the intake temp sensor intact too!! Woohoo!



Case covers and race frame protections from GB



Carbon tank sliders, essential for the wide arse tank!


Lithium battery.. can't believe how little these things weigh?!!


Braided lines and SS Carbon rearsets...


New surround for the smashed up dash.. Only thing broken is the LCD speedo. Not super urgent and this one seems to do the trick.


Got to finish the suspensions mods yet.. think we've got a shim stack sorted, just waiting on some custom guides to fit the new springs.

[Negrogrande]

nice work

[Leezx10r]

Looking good mate, keep the pics and updates coming, everyone loves a bike build


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[Turtle]

Siiick. Can't wait to see the completion mate.

[Marshy]

Rob H. says he sent the new spring bushes today, so hopefully they'll arrive tomorrow and the forks can go back together!

[Turbo]

Rob H. says he sent the new spring bushes today, so hopefully they'll arrive tomorrow and the forks can go back together!

^^ Amazing!! What a legend.
Can't wait to give em a try.

[Turbo]

Another update on the build progress..

The bike sat outside at the wreckers for a while, it must have rained as the discs were not in great shape..




Whipped out the rotor hone and went to town on the discs...




They came up a treat and should make an excellent base layer when I put the Vesrahs in!




Next up was the exhaust system.




Took a grinder to the collector and saved myself about 10kg in the process!!




Then I ground off the thingamy bits so that the Y-Pipe would fit on...




The headers were looking a little tired so I set about them with some metal polish.





I think they came up pretty well and look great with the Arrow GP2 mid-pipe and muffler.




It's a decent length, all fitted up, so I'm hoping that'll translate to some good mid-range on the dyno!




If nothing else, I reckon it looks great!




Last thing for this evening was fitting the new gearing and chain... Starting to look sort of like a bike now!

[Marshy]

Looks unreal!!

[chubb]

Amazing what a little bit of elbow grease will do

[Leezx10r]

Me like the pipe!


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[Negrogrande]

Well done, looking good

[senator8]

Nice work Owen.

[dan]

Lovely!


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[Turbo]

It's taken a while but we've finally come up with a winning fork solution.
It's involved A LOT of R&D, some brand new parts...



and even some custom made bits....




but happily the forks are now done, so on they go!




Now that the front end is coming back together, I can re-fit the calipers with new front braided lines and Vesrah brake pads...




Starting to look pretty trick down here .....




Last thing for tonight are the clip-ons, bars, grips, levers and switches etc.. Almost time to get out on track!!

[stevem]

Good to see Owen.

[Leezx10r]

You have been busy! Looking good mate, keep the updates coming.

[dan]

dunno about those blue brake lines haha


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[Turbo]

dunno about those blue brake lines haha

They keep the fluid much cooler than the red ones

[dan]

haha hook up air con

[Turbo]

Tonight I changed the brown slop out for racing oil and stuck on a new filter...




Then back behind the radiator, to the coils, to fit the quick shifter harness..




Thread that back up the bike to the control module for the Quickshifter, in the tail... This has NFC for control via your phone!




Loving the new MKIII Annitori colour scheme too...
"I LOVE GOOOOOOOLD!"




The new shift rod and microswitch get installed...




That makes this side... pretty much done! (The shock is in the middle so it totally doesn't count as this side )

[Mr.Ed]

I was gonna agree with but then I noticed you missed the lock wiring and the debatable side stand (I keep mine on unless racing tbh)

[Turbo]

I was gonna agree with but then I noticed you missed the lock wiring and the debatable side stand (I keep mine on unless racing tbh)

Hahah, yeah the side stand has a bit of.. character? I'll be removing that for sure.
Not done any lock wiring at all. With my shoulder still screwed, it'll be a while before I'm racing again.

[dan]

My shoulder is alright though....


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[Turbo]

My shoulder is alright though....

I'm sure you and your new Kwaka will be very happy together

[Metal-Man]

Lookin good sicko ;-)

[Turbo]

Replaced the old, smashed fuel tank bracket with a shiny new one from Yamaha!




The front end smash left me without intake temp and pressure sensors so I had to find some new ones... Checking the wiring here.






Then re-terminated, no error codes so - good to go!







Next to make a custom, progressive quick throttle from some old PVC pipe. If you've not seen it done before, here's how it works:
First I had to cut out a section of the PVC pipe...







... then glue it to the throttle tube...







then a smaller section on top, glue that down...








then dremel to the required thottle delivery cam shape. In this case, the standard amount of throttle when cracked, to help avoid accidental high sides, then progressively getting more aggressive after that...







Dremmel a wee slot for the throttle cable. This part will actually make it less snatchy than the oem throttle when first cracked...







Nibbler on the assembly to allow for the new shape...








before putting it all back together....







Chucked on some new levers...








Fitted a new racing front reservoir and bracket...







It's not a Honda but damn, I love the HRC rear reservoir tube... fitted.






Scratching around for things to put on now! Probs off for a flash and dyno soon...

[dan]

*like*

[Leezx10r]

Looking good mate, cannot wait for finished project. Well they never really get finished, but you understand

[Turbo]

Looking good mate, cannot wait for finished project. Well they never really get finished, but you understand

Thanks Lee, everybody. Me neither, It's getting so close now!!

[Row]

This is a great build thread. Really enjoyed reading this.

[Metal-Man]

is the R6 08 rear master cylinder a common problem?
mine feels like its a switch ... it's either on an locks up rear wheel, or it's off. Nothing in between

[Marshy]

is the R6 08 rear master cylinder a common problem?
mine feels like its a switch ... it's either on an locks up rear wheel, or it's off. Nothing in between

This can caused by some aftermarket rearsets (eg Vortex), when the angle of the piston is not dead-straight into the master cylinder. When you press the lever, does the piston move into the m/c exactly evenly, or on an angle?

[Turbo]

This is a great build thread. Really enjoyed reading this.

Thanks mate! Glad you've enjoyed it.
I've really enjoyed building it!!!

is the R6 08 rear master cylinder a common problem?
mine feels like its a switch ... it's either on an locks up rear wheel, or it's off. Nothing in between

Interesting comment, do you have braided lines? We were discussing the merits of oem lines on the rear brake to get a more progressive feel, just yesterday.
The 'squish' from the oem lines would make it less like a switch and give a bit more of a progressive feel to it.
I have the rear oem on my race bike and wanted to try braided on this build to see which I preferred.

[WRCPUG]

awesome build thread

[Turbo]

awesome build thread

Ta mate! Coming soon to a track near you....