2001 R1 Race Bike Rebuild...

[Damon]

Hi all,

Following on from this thread

https://www.bikechatforums.com/viewtopic.php?t=206535&highlight=damon

I ended up buying my friends R1 and selling my 1999 R1 to help pay for it. I got it for £1500 in the end which is what he paid for it before I crashed it at brands hatch.

Picked it up last night and had my first proper look at it this morning. It is the first I've seen of it since I was chucked off over a month ago. I am going to rebuild it into my track bike for next year, but first port of call is to get the hundreds of tonnes of gravel out of the engine bay and give it a clean up to see exactly what needs replacing.

Anyway, here she is

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs463.ash2/73689_10150315338985497_784455496_15894345_4039844_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs581.ash2/150375_10150315339195497_784455496_15894347_5182666_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs889.snc4/72232_10150315339310497_784455496_15894349_4793123_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1149.snc4/149157_10150315340415497_784455496_15894379_998148_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs276.snc4/40128_10150315341365497_784455496_15894392_4007409_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs457.ash2/73053_10150315342905497_784455496_15894411_6219046_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs991.snc4/76492_10150315343990497_784455496_15894440_4289337_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs563.ash2/148591_10150315345580497_784455496_15894444_4880614_n.jpg

[Frost]

Subframe is clearly twisted.

[jdm]

Chain needs tightening i think!!
____________________
Good women make me happy, bad one's even happier!
Current Bike = '97 YZF600R Thundercat

[warped one]

Why not hang a minger until it falls out the back?
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amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[Frost]

[Damon]

[CHR15]

what are those tyres? they look awesome.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[woll]

Dam you Chris i saw you'd posted in show and tell and i though yey turbo updates... but no your asking about tyres
Anyway Nice bike damon
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[Damon]

[Wafer_Thin_Ham]

Got rid of that gay iridium screen yet?
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My Flickr

[Damon]

[Wafer_Thin_Ham]

[Damon]

Update:

I now have a hawaii beach garage after taking the panels off the r1 today... Well, I say hawaii, it's more like brighton sea front; cold, shit and full of gravel

I have replaced the bent levers with a set of pazzos and managed to get the banana engine bolt out without snapping it R&Gs have been stuck on and the whole bike has been given a proper cleaning. I have also removed the ignition as I don't really need a key. I'm just going to splice in a on off switch and leave it at that.

Pictures coming soon... My trusty iphone became a bit broken last week.

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs576.ash2/149859_10150319093255335_591840334_15857846_7213419_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs454.ash2/72696_10150319040970335_591840334_15856859_8071772_n.jpg

[warped one]

Best place for an Iphone IMO.

Did you end up on the floor aswel?
On top of the paint can would make my day.
____________________
amnesia - Never in the history of usernames has one been more accurate. Warped indeed. You sir are a fecking oddball.

[Damon]

[Damon]

:Update:


So finally got myself a new phone with a camera so can carry on with some snaps.

Yesterday I removed the ignition and wired in an on off switch in its place. I also removed all the electric controls, started shortening the loom and wired in a new starter button.

Here is how she stands now. Last week I removed all the panels, gave her a bit of a clean and removed the tonnes of gravel. I also managed to get the banana'd front crash bung out with a big vice. Also, It turns out the front ali fairing brace was twisted and not the forks phew...

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs417.ash2/69567_10150342126055497_784455496_16312347_5295450_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs118.snc4/36244_10150342126655497_784455496_16312351_2669989_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1200.snc4/155236_10150342126890497_784455496_16312353_184583_n.jpg

I knocked up a blanking plate for where the ignition switch used to sit. I will drill a 12mm hole in the middle to fit my new starter button. Should tidy everything up a touch


https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs591.ash2/154365_10150342127405497_784455496_16312355_3026336_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs893.snc4/72646_10150342127515497_784455496_16312357_5680390_n.jpg

[Tim..]

Are all the wires tested and tidied up now?
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Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[Damon]

[Wafer_Thin_Ham]

Why not just wire to the kill switch like everyone else does?

Seems crazy to wire in an extra switch....
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My Flickr

[Damon]

[Damon]

little update.

Marked out the blanking plate ready for drilling and drilled a pilot hole. I then worked my way up the drill bits until I reached the correct size for the switch.

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs757.snc4/65721_10150342643575497_784455496_16320320_64629_n.jpg

Next I got the dremel out and started to smooth over and around the plate. Once fairly smooth I used some 600 grit wet and dry on a sanding block to finish off the area. I gave the rest of the yoke a key too, ready for priming.


https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs597.ash2/154934_10150342643820497_784455496_16320325_6663476_n.jpg

[Damon]

Update:

Spent today wiring in the datatool revlight. No dramas to report, everything seems to be working properly from what I can tell. I will test it properly once I start the bike.

The main progress I made today was painting the top yoke. I will write out a bit of a step by step of how I did it.

First of all I prepped the yoke by giving it a good roughing up with some 400 grit wet and dry. I then followed with a clean cloth to remove any dust created from sanding.

I wanted to mask off the yamaha tuning fork logo so thought I would use apply some petroleum jelly. I tried to make sure it only covered the logo but ended up having a few problems. After the first coat had dried I wiped my finger over and there was vaseline in parts of the yoke that really didn't need lubing cue the paint flaking off and leaving patches.

Back to the drawing board... I know! blue tack. It was perfect Will definitely be using it as a mask again when the need arises.

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs379.ash2/65793_10150344441775497_784455496_16345183_6661072_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1355.snc4/162737_10150344442525497_784455496_16345186_3349412_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1218.snc4/157023_10150344443925497_784455496_16345209_3100972_n.jpg

I gave the whole thing a sand and clean again after the vaseline incident and we were back in business. I followed with 4 coats of primer, using a hair dryer inbetween each coat. I then left it for an hour and applied another 4 coats of redoxide primer.

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs118.snc4/36242_10150344444165497_784455496_16345211_5168088_n.jpg


https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1120.snc4/148257_10150344444475497_784455496_16345216_4597722_n.jpg

I left the yoke to dry for 30 minutes and then moved to a radiator to help with curing before I applied the colour coat.

Half a day passed and It was ready for the colour coat I lightly sanded the primer with 600 grit wet and dry and gave the piece a "mist" colour coat. I have found doing this for the first coat when spraying really helps to stop runs on the later coats. I also heated up the yoke slightly with a hairdryer to help stop runs once again.

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs380.ash2/65883_10150344448080497_784455496_16345264_605941_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs712.snc4/63192_10150344448925497_784455496_16345284_548748_n.jpg

I sprayed 4 coats and left for an hour. Then sprayed another 3 coats. I made the last coat as wet as I dared. All went well without a single run... phew

After an hour passed I moved the yoke back to the radiator to help with curing once again. I then began with operation house clean up. Everything upstairs was covered with a fine layer of over spray. Brilliant!

Here are a few snaps of the rev light fitted to the loom


https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs715.snc4/63537_10150344445640497_784455496_16345236_6030380_n.jpg

https://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs407.ash2/68534_10150344446605497_784455496_16345245_3063920_n.jpg

[CHR15]

how much did the rev light thing cost you?
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[Damon]

[Damon]

Update:

Fitted the yoke back to the bike and wired everything up

https://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs242.snc4/39417_10150345092320497_784455496_16354318_3052775_n.jpg