v reg 99 Yamaha t-cat project (finally finished)

[neiloggy1]

Finally picked the t-cat up today

and had a spare 2 hrs to start work on it.
I think it's in worse shape than seller made out but the price was good for what it is.
So first job strip down and checkout damage
Forks bent
Front Lh disc cracked
Front fender cracked
Both front side fairings cracked
Rear subframe bent

I bet most would walk away but ill sort it

By next post hopefully have rear end sorted and rest of front end stripped down

Got three choices with frame
Bend back myself
Send to frame alignment shop
Or get replacement frame
pics before stripdown
https://s18.postimage.org/w8salf7mh/IMG_0581.jpg

https://s15.postimage.org/5bckesji3/IMG_0582.jpg

https://s14.postimage.org/hx1ccyuxd/IMG_0583.jpg

https://s11.postimage.org/la0o5qpmr/IMG_0588.jpg
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98 zx9r

[Dracon]

You could always do the R6 tail mod, it involves cutting the back end off, which wouldn't be a bad thing in your case!

[neiloggy1]

[lilredmachine]

[neiloggy1]

Ok so it turns out that that a tail chop to an r6
May be an option
You are right rear subframes can be bought for as little as 60 quid
Am I right in saying that the rear sub on an r6 is separate from its frame and can be simply welded to my tcat
As I know a good welder
wow just a bit bent
https://s7.postimage.org/7586vgsln/IMG_0586.jpg
https://s9.postimage.org/o691lny7z/IMG_0585.jpg
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98 zx9r

[Pol Anorl]

chains slack subframes straight.

out of curiosity how many pounds did this take from your wallet?
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GOOD GAME BODYGUARD: https://i.imgur.com/8WePGgf.jpg
20:30:37 Pyro.: I don't sort of like men, I take every advantage to choke on dick.
Jewlio Iglesias: You live in Liverpool - Chances are, the front door has already been kicked off the hinges

[neiloggy1]

[lilredmachine]

[mysterious_rider]

[neiloggy1]

Finally the forks arrive time to replace these bent ones
the new ones Look and feel to be in good condition and bargain at 150
So had a spare hour to tinker
Stripp rest of front end down
and test fit new forks

Just wanted to make sure it's all straight no freeplay and all is good
So all calipers are also off for strip down reseal and repaint
Next jobs to sort
rear end needs straightening or r6 mod
replace suspension linkage bearings
Replace front discs (one is cracked)
Major cleanup
Check all bolts nuts replace any rusty
Service oil filters coolant plugs
Check clutch as it feels abit stiff
Refit calipers
Then finally decide on a color scheme and refit plastics
can't wait to see the end and finally ride it
https://s15.postimage.org/q5hz6c1u3/IMG_0661.jpg
https://s16.postimage.org/r3lmasu6d/IMG_0588.jpg
https://s12.postimage.org/9veupnb8t/IMG_0659.jpg
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98 zx9r

[stonesie]

[neiloggy1]

i have probably done every job on a bike and iam a confident mechanic
but i have never changed fork oil
never needed to but cheers for suggetion ill research and do that
another job on the list and possibly next one as forks are just nipped up at the moment
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98 zx9r

[stonesie]

After talking to an expert (Reactive Suspension) his opinion is that the fork oil that bike manufacturers use is cheap crap, if those forks have never been opened then it will be totally ruined by now.

[neiloggy1]

Guess new fork oil it is then
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98 zx9r

[neiloggy1]

So today managed to straighten the rear subframe
Simply got a scaffold bar which was 8ft long (easy leverage)
Then ratchet strapped the frame in 3 places to a steel fence
also with measured blocks of wood so the main frame wouldn't twist
Basically a home made jig
Heated the subframe with 2 blowtorches for a while
Then simply bent the subframe back to its normal shape
In all it took about an hour
i had to make lots of measurements along the way to make sure it was perfect and all is good
Bike is now at basic welding I'm having some support bars
Welded on and seams rewelded
should be back just after new year
Also stripped the forks down put new seals in and fresh oil
Before sending frame off
In mean time im going to start on the plastics (sand plastic fill sand prime sand)
im not going to topcoat yet until the bike is fully finished
also going to paint and reseal the calipers while the frames away
any ideas how to cleanup this exhaust
https://s1.postimage.org/qn7vx405b/IMG_0660.jpg
more pics on progress soon
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98 zx9r

[rhys1005]

Ok gheeze fine il buy your crash bobbins.. How much?

[Diddylord]

to help with your exhausts what i would to is just jet wash the worst of the dirt of and then get a toothbrush and some of this stuff.
https://www.amazon.co.uk/s/?ie=UTF8&keywords=autosol&tag=googhydr-21&index=aps&hvadid=7213668373&hvpos=1t1&hvexid=&hvnetw=g&hvrand=1237014044547453856&hvpone=&hvptwo=&hvqmt=e&ref=pd_sl_75bb020bur_e

works really well but stinks as you do it, will get that looking new again with a bit of rubbing.

[neiloggy1]

The exhaust actually cleaned up easier than I thought with a little wd40 and elbow grease
Also got the frame back from the welders last weekend so I've been really busy Working on the bike since then
I have spent about 16 hours rubbing the frame and swing arm down for paint
Was in 2 minds on color for the frame
So first I sprayed the swing arm silver and I didn't like
So rub down Again and now is sprayed in Matt black and it looks the muts knackers
Cleaned shock rebuilt rear end
Second hand front discs fitted
New bushes pressed into rear shock linkage
I'm now onto the calipers rear exhaust and foot hangers
Pics and more info soon as I get time
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98 zx9r

[neiloggy1]

[Xenocide]

I've got a blank tank, frame + MIGHT have disks - i can't remember.

PM me if you're interested. I make good price for you mister, verrrry nice.
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KTM LC4 400 | Honda VTR1000

[ian505050]

I have some new brake pads for a thundercat and a dark screen that you can have if needed, you would just have to cover postage, Offers there if you need them.

[neiloggy1]

well i needed the cat to get to work so i got some fairings for cheap off ebay.
while waiting for them to arrive i put it back together fully
greased all necessary bits and washed it down.
fairings finally arrived a week later so tools out again and 3 hrs later job done.
i been waiting a long time to take her out fully dressed so out i went.

now while out i wasnt entirely impressed with the performance compared to the zx6r i previously owned but was more comfortable guess they are a good first bike

anyhow here she is fully finished and working
https://s4.postimage.org/g15d4vurx/IMG_0777.jpg

https://s11.postimage.org/imxd0eywj/IMG_0776.jpg

https://s7.postimage.org/psnp53pbf/IMG_0778.jpg


but sad ending to this even tho i thought she looked ok i was not happy with the performance
so i sold it and bought this instead
https://s12.postimage.org/hjdnkfg6l/IMG_0781.jpg
and now im very happy 1000cc of great performance and the new thunderace doesnt need a thing just a good clean and a few extras

so new thread soon and in better detail cheers all for advice
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98 zx9r

[Ja7]

Nice work there looking good