1994 CBR600f repair... a tale of misery and frustration.

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

EDIT: new problem, see page 3!

So i dropped the bike last week, and it's now time for it's MOT.

So, to the toolkit!

the bike started like this

https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/263409_2024039614369_1645368025_1884609_4215968_n.jpg
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/263537_2024039374363_1645368025_1884608_3191237_n.jpg
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/270313_2024039174358_1645368025_1884607_5053585_n.jpg
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/282043_2061883840451_1645368025_1930583_1046876_n.jpg

Then knowing me, i managed to drop it. won't go into details, it's embarressing.

I needed it for work so i ripped the fairings off and slapped a headlight on.

https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/283851_2076111156125_1645368025_1950436_7516579_n.jpg

Sorted.... Or so i thought....

Took it for a ride. Misfiring on 2 cylinders, petrol dripping from the overflow on the carbs and billowing white smoke from the exhaust, and then i noticed the oil leak.... when the oil started burning off the hot exhaust...

https://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/281298_2076257119774_1645368025_1950641_3338885_n.jpg

Not good.

So, it's been off the road for a month now. I've been waiting till i get paid, which is in 2 weeks, so i'll be buying a new sump for it.

So today, i've done this.

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/294463_2110677220255_1645368025_1993528_132680_n.jpg

Golly gee whizz holy jumping catfish.

I've now cleaned out the carbs, but i can't start it due to it having no oil so i'l have to wait and see if it's sorted.

Another problem i found was that the right switchgear would turn with the throttle, so a quick peek inside showed me that the little pin had snapped. So I went to town with the dremel, a drill and a screw, and i've permenantly bodged it... should hold Thumbs Up

No pictures from here as it got dark and was pissing with rain.

Plan for tomorrow after work is to put the fairing back on, and get the clocks and light set up again. The problems i face are with the lower fairings, as most of the bolts are missing or rounded off, so a bolt set off ebay will help with that.

We'll see what else it needs when i get paid and take it for it's MOT Rolling Eyes

Dunc

Casper · World Chat Champion Joined: 12 Jul 2010 Karma :

As you were getting another sump why did you not just get that one welded up so you could still use the bike. Not ideal but it would have been cheap fast transport.

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

I wouldn't trust it.

I'm getting a lift to work now, so i don't really need the bike at the moment. but i'd much rather buy another sump than use that one when it's welded.

Of course, i'll get it welded when i get the new one, just so i have a backup.

Dunc

Casper · World Chat Champion Joined: 12 Jul 2010 Karma :

I meant weld the broken part and plug. Its only till pay day and bin it when the new one arives.

The Tot · World Chat Champion Joined: 11 Jun 2004 Karma :

That same thing happened on my 6R. Sometimes it's a lot easier to get a used sump and replace it rather than having to weld it. I didn't have the luxury of knowing anybody with a stick or mig welder with the right consumables for the sump Crying or Very sad

. But it would have been my only option had I not found a spare sump.
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The Tot 2007 Yamaha R1 4C8 2002 Yamaha FZS1000 Fazer &
www.youtube.com/Titot182 for your bike gear reviews and pop punk covers
Earl Of Easycore Pop Punk Will Never Die!

Serendipity · World Chat Champion Joined: 07 Jun 2006 Karma :

I managed to break the sump on my CBR using only my powerful muscles and a ratchet set to the wrong direction. Sadly my brain took no part in this transaction until the loud cracking noise, by which time it was too late… Embarassed

That was in 1999 and at the time it was very easy to find a used sump from a breakers for a very small handful of beer tokens. I assume that the almost ubiquitous nature of the Hornet means that used parts for this motor are still easy to find.
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2016 CBF1000F - Commuter heaven | 1994 CBR600FR - Awaiting defibrillation

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

Righto, did some more work getting the fairings back on.

Bit of a nightmare as all the bolts i had are now lost.... We built a nice big shed, and moving the bike from the bottom to the top of the garden has resulted in me 'mis-placing' all the bolts

So i need to wait till i get paid so i can buy a set.

Anyway.

Managed to slap the front fairing on, set up the light, speedo, and wiring all routed properly.

https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/296796_2113203403408_1645368025_1997284_3028927_n.jpg

This is how it's sitting now.

https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/295752_2113148002023_1645368025_1997253_3536639_n.jpg
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/291892_2113148482035_1645368025_1997254_885098_n.jpg
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/298829_2113149162052_1645368025_1997255_6427736_n.jpg
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/296503_2113152882145_1645368025_1997258_3755508_n.jpg
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/254764_2113154122176_1645368025_1997259_7845867_n.jpg
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/294566_2113155002198_1645368025_1997260_2662146_n.jpg

Now, i've noticed my downpipes are a little under the weather, so i might take them off when i come to do the sump change, and spray them up with some high temp silver paint... we'll see though.

Need new bolts and studs for them too, as the ones on it are horrid looking. i'll spray them with some WD40 every day for the next week... hopefully that'll free them up.

ALSO need to get some indicators for her too. no idea where i'm gonna get them as there's none for this model on ebay cheap, so i might just drill some holes on the fairing and stick my mini indicators in, pass the big holes off for 'ram air intakes' Wink

Also.

https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/299010_2113207403508_1645368025_1997286_4444370_n.jpg

RHS fairing nice and clean, fixed, and matching the LHS Mr. Green

Dunc

N cee thirty · Banned Joined: 31 Jan 2010 Karma :

Looks alright without the full fairings Thumbs Up

____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

fiveus · Spanner Monkey Joined: 29 Oct 2009 Karma :

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

So apart from the smoking issues i had, and the exhausts not coming off properly, it's been pretty simple!

Had a problem today with the battery being completely dead, and i found that the remote start on the alarm had been wired up.

So i took that off and made sure the connections were taped up to stop them joining up again.

Then i put it all back together.

https://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/316925_2142432134108_1645368025_2036120_1097591_n.jpg

What's better, that or this?

https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/295752_2113148002023_1645368025_1997253_3536639_n.jpg

MOT on wednesday so i shall be dropping it off tomorrow, here's hoping i don't run into any more problems!

Dunc

Darth · World Chat Champion Joined: 14 Mar 2008 Karma :

Looks quite cool with just the nose fairing on. Strange cos I usually hate bikes designed with half fairings! Confused

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Harold_Shand wrote: I suppose it's like anything, you get your fingers burned when you start out, you learn from it and eventually become a complete arsehole about the whole thing.

dannyjohnson · Banned Joined: 22 Aug 2011 Karma :

Looks alright without the full fairings Thumbs Up ,very nice
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dannyjohnson

Benson_JV · World Chat Champion Joined: 04 May 2010 Karma :

Full fairing. Duuuh Wink

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Willson - "If you go out on that CBR600 in the winter, you're going to do more miles on your side than on your wheels."
Riding: CBR600FW Driving: Audi A6
Previous Bikes: '96 Bandit 600, '96 GPz305

Serendipity · World Chat Champion Joined: 07 Jun 2006 Karma :

Nice one. I was worried that the smoking was a precursor to a post along the lines of my engine went bang. Glad you got it all working.

Re the fairing. I used to ride mine without the side panels quite a lot in the summer and it makes a surprising difference to the weight of the bike. However in cooler and wetter weather having the lower fairing fitted makes a massive difference to how warm and dry your legs stay. It’s less important if your journeys tend to be at urban speeds, but once your hit 50mph+ the wind and rain just flows around your legs.
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2016 CBF1000F - Commuter heaven | 1994 CBR600FR - Awaiting defibrillation

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

Just dropped it off for it's MOT.

The stubby is the only thing worrying me at the moment, so here's hoping it passes. if not, i've got 7 days to put it back in for a re-test for free, so it'll be going in with the baffle in, if it gets delivered in time.

Took it for a run up the A1, and it's misfiring like a mofo... looks like the spark plugs need changed, but i can do that after the MOT as it's not majorly important at the mo.

Anyway, that's me for now. shall post up tomorrow with results.

Dunc

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

How did you get on with the MOT ? Pass?
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1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

Failed miserably.

Indicators flashing more than 120 times per minute... i never noticed this, they were fine when i checked.

Headlamp aim beam image kicks up to the offside

Rear reflector missing

Offside rear footrest missing.

Oh well.

Also, it's smoking like a mofo just now... and it's misfiring.

My guess is that the plugs are fowled up and need changed, as that's the one thing i didn't do.

that'd cause the petrol to wash the bore, and oil would seep up, and would burn.... right?

Either way it's off the road till next year.

The examiner said it was a great condition bike for it's age, best one he's seen in a while which is reassuring. Nothing wrong with any bearings or anything else important, it's just the bits that are missing etc. Also mentioned the subframe had been modified, but it's not dangerous in any way... i might want to think about getting a new one welded on though.

New fairings are needed, since they are off the F2, and mines is actually an F3 with F2 bits on it, but i was getting those anyway, and a new exhaust is needed. he said the stubby was 'offensive'.

funny though, because the exhaust hasn't been mentioned on the certificate. when asked why, he said 'don't even get me started on the bloody exhaust'.

SO...

Plan of action:

new exhaust - £100
New CCT - £70
New footpegs all round - £40
New headlight - £20
New indicators (originals, since i've got these little cheap arrow ones on it) - £30
new fairings all round - £300

Yes, i know i've got more money than sense, but i plan on keeping this bike for a good few years, and i'd rather spend the money now and have it sorted, and have a pretty much new bike.

Dunc

0l0dom0l0 · World Chat Champion Joined: 21 Oct 2009 Karma :

I can sell you a standard can that'll fit straight on if you're interested?
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CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

depending on the price, i might be. not really looking for a standard can but at the right price i'd be cool with it till i can get a proper can that doesn't make it run terribly.

Pm me.

Cheers

Dunc

0l0dom0l0 · World Chat Champion Joined: 21 Oct 2009 Karma :

Dw I've found one on ebay that's in better nick and it's only £20 so you'd be better off with that Laughing

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CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :

No worries. bike's getting laid up for a couple months till i can afford the parts again, so not be buying anything for a while Laughing

Dunc

serlant · Brolly Dolly Joined: 06 Jul 2009 Karma :

First thing, camchain tensioners, £70? they better be made of titanium, https://ape-store.com/shopsite/page4.html
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04 CBR1000RR, 1995 Husqvarna TE410, 1998 VTR1000(Sold), 1990 XJ600(sold), 1996 KH125(dead and sold)

Casper · World Chat Champion Joined: 12 Jul 2010 Karma :

dextersaurus · World Chat Champion Joined: 25 Mar 2009 Karma :