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2003 R1 5PW Rebuild (Pic heavy)

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Nope.
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Joined: 16 Feb 2011
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PostPosted: 00:30 - 12 Feb 2016    Post subject: 2003 R1 5PW Rebuild (Pic heavy) Reply with quote

Hi All,

So in august last year I bought a 2004 registered 2003 build 5PW. It's a category B write off after a small incident with an MPV by the previous owner (a friend of mine). It'd been partially rebuilt with new bearings all round (apart from the swing arm), fork rebuild, brake rebuild etc. What it looked like when I got it:

http://farm1.staticflickr.com/617/22669217769_2e096639a0_z.jpg

http://farm1.staticflickr.com/568/22643144007_f7b621711b_z.jpg

It had a few nice bits on it, namely a full Akra system, K&N and a PC3. It also came with a set of Harris rear sets that weren't installed.

I did also install a set of headlights Laughing :

http://farm6.staticflickr.com/5747/22440294683_328a8bb539_z.jpg

Shortly afterwards I high sided it on a roundabout and broke my collar bone.

I set about getting the R1 road worthy again. It desperately needed a new clutch so I fitted one I found cheap on Demon Tweeks (Viper, for the record. DON'T BUY THESE!):

http://farm1.staticflickr.com/773/22643145457_fd15001328_z.jpg

http://farm1.staticflickr.com/713/23047906372_ec192180c1_z.jpg

and it was terrible. Slipped almost as bad as the original one! SO I installed a barnett top plate.

It certainly sorted the clutch out! Dance!

I'd been riding it around in primer for a few months but on christmas eve I decided to plasti-dip it. I did it in the dark in 4 hours and it didn't go brilliantly Laughing

http://farm1.staticflickr.com/732/22440296683_65b02bfe35_z.jpg

I also vinyl wrapped the tail:

http://farm1.staticflickr.com/734/23035457576_cbc3633f5b_z.jpg

It looked very ratty, but still rode like an R1.

Here it is having a new set of Metzeler racetec's fitted:

http://farm6.staticflickr.com/5650/22643096988_317450324d_z.jpg

Unfortunately after a few more miles and a story I won't go into here (No, I didn't crash) it started making an interesting noise... the kind of noise you never want an engine to make. Ever. Like a really angry man was trapped inside my casings with a hammer. So I dropped the engine:

http://farm1.staticflickr.com/610/23047907972_0c1e2ce094_z.jpg
http://farm6.staticflickr.com/5730/23061501535_534cb2d145_z.jpg

The top end was in remarkably good nick:

http://farm1.staticflickr.com/655/23047908322_5726ac3959_z.jpg

I was planning to rebuild the engine but once I priced up all the bearings and the work it just seemed uneconomical. Then I got hold of a rebuilt motor with the following spec:

    APE SLOTTED CAM SPROCKETS AND APE MANUAL CAM CHAIN TENSIONER
    YEC THINNER HEAD GASKET
    NEW PISTON RINGS, SHELLS, ROD BOLTS ETC
    NEW SECOND GEAR 5JJ-17221-00
    PETE BEAL PORTED HEAD.
    ALL VALVE SEATS RE-CUT TO 3-ANGLE
    ALL VALVES OIL SEALS CHANGED REPLACED WITH NEW ONES.


It was quite reasonably priced so I snapped it up. It's literally never been fired:

http://farm6.staticflickr.com/5628/22440298903_072ab4d199_z.jpg

http://farm1.staticflickr.com/653/22438715174_2b9a3322cd_z.jpg

Whilst dropping the engine I discovered why the bike was written off Cat B. Theres a small crack near the rearset mount on the left of the frame. I can get this TIG welded up but whilst I'm here I figure I may as well use a new (to me at least) frame with a clean history.

So I obtained a new frame. It's got a clean V5, never written off etc.

It's been crashed, but theres only a scratch to show for it. No biggy.

In the mean time, I stripped down the original engine and discovered the source of the noise. I dropped the sump off and was greeted by the following lovely sight:

http://farm6.staticflickr.com/5831/22641977648_2a901c0b86_z.jpg
http://farm1.staticflickr.com/564/22439173983_aca44dfeab_z.jpg

The clutch has completely shattered. Brilliant.

http://farm1.staticflickr.com/737/22438715424_2e3b21cc97_z.jpg
http://farm6.staticflickr.com/5812/22669223519_614878f663_z.jpg
http://farm6.staticflickr.com/5710/23047910002_0349c2ab32_z.jpg
http://farm1.staticflickr.com/626/22643150337_3aab9d6ed5_z.jpg

It's gone everywhere so I'm going to need to split the casings. Good thing is it doesn't appear at first glance to have done much damage so the engine may be salvageable with a complete strip down, a good clean out and a new set of gaskets.

Still, got my new engine to go in Very Happy :

http://farm1.staticflickr.com/767/22642024897_53717ffa42_z.jpg

I set about stripping her down:

http://farm6.staticflickr.com/5696/23060377225_98614d38c7_z.jpg

It would appear that the reason my original frame was written off is due to these cracks:

http://farm1.staticflickr.com/691/22641977888_104870b7a9_z.jpg

http://farm6.staticflickr.com/5677/23136116441_fd942a91d4_z_d.jpg

http://farm6.staticflickr.com/5639/22503378703_43ca005c42_z_d.jpg

Also painted the side stand:

http://farm1.staticflickr.com/688/22501875014_15ee838ba4_z_d.jpg

Today I finished stripping down the old frame and swing arm.

Forks out (dropped the triple out, then took the forks out of the triple):

http://farm6.staticflickr.com/5639/22503378703_0275446438_k.jpg
http://farm2.staticflickr.com/1675/24931391766_7b0555d4ef_k.jpg

Then I got the shock out:

http://farm2.staticflickr.com/1568/24864383741_8e7a71c2b4_k.jpg

Then I needed to remove the swing arm pivot. Well, I've never come across a nut this seized! I had a go with a rattle gun for a good 20 mins with no luck. Heated it up with a blow torch and tried again, no luck. Tried a steel bar on a wrench, no luck.

Finally, I got my friend to come over with his 5ft breakers bar, we heated the nut up and then the two of us managed to get it undone. It was obviously torqued well over the specified 120~Nm!

http://farm2.staticflickr.com/1616/24931399476_641f158fa1_k.jpg

Now the swing arm is out, I had to remove the bearings (the frame, swing arm and subframe are getting powder coated next week and so the bearings need to be removed as if you powder coat with the bearings in the grease will run when the part is baked and ruin the powder coat). I used a halfords trolley jack handle as a drift, heated up the swing arm and hammered them out:

http://farm2.staticflickr.com/1711/24598419829_e9f4a1ff42_h.jpg
http://farm2.staticflickr.com/1533/24670549790_5752b50896_h.jpg

I then set about removing the other swing arm fittings. All came out swimmingly apart from one very corroded bobbin bolt Evil or Very Mad. I've got to have a couple of new threaded collar's welded in where they've fallen out anyway so I'll just get the engineering firm to deal with the stud when they TIG in the new collars (And re-tig the existing ones).

Thats about where I am now. I've completely stripped the Frame and swing arm, I've just got to get the tray out of the sub frame and get the swing arm sorted then It'll all be ready to go to the powder coaters.

Hope this is in someway interesting to you guys. I'll try and take more pictures in the future Laughing
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Joe
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PostPosted: 08:13 - 12 Feb 2016    Post subject: Reply with quote

Good stuff Thumbs Up
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ride_to_die
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PostPosted: 11:50 - 12 Feb 2016    Post subject: Reply with quote

Looks interesting. Moar please.
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bladeblaster
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PostPosted: 16:10 - 15 Feb 2016    Post subject: Reply with quote

looks like fun
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Nope.
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PostPosted: 17:54 - 16 Feb 2016    Post subject: Reply with quote

Did some work this weekend. Play was stopped Saturday as I had to go pickup a friends new purchase in my Mondeo (a 1991 which is solely used for moving motorbikes and engines Laughing)

http://farm2.staticflickr.com/1565/24976331011_efda3d39c2.jpg

Got that back to his, fell asleep after an 8 hour drive, etc.

Sunday, I decided to get the last piece of frame ready for coating so I took the tray and wiring loom out of the subframe:

http://farm2.staticflickr.com/1570/24438992814_2418ec8d92.jpg
http://farm2.staticflickr.com/1541/24442772073_a2f8802475.jpg

I needed to get some work done to the swing arm so I dropped it off to a local engineering firm today. They're going to turn up some new threaded collets to replace some that have fallen out (The chain guard screws into them). They're also going to remove the stud that snapped off in the right hand bobbin mount. When it's done I'm going to take it to a TIG welder and get them to TIG the collets into the arm. Then I can take the whole lot to the powder coaters for blasting and coating.

The bottom triple was looking a little sorry for itself with lots of horrible corrosion damaging the lacquer etc. so I cleaned it up and prepped it for painting:

http://farm2.staticflickr.com/1651/25043306636_bc0e522fa9.jpg
http://farm2.staticflickr.com/1524/25043303996_b74d0d586c.jpg
http://farm2.staticflickr.com/1577/24442772603_2628837fd1.jpg
http://farm2.staticflickr.com/1471/24951519742_5f405e4552.jpg

I'm leaving the primer to set, then it'll get painted black tomorrow.
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c_dug
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PostPosted: 18:10 - 16 Feb 2016    Post subject: Reply with quote

Cool stuff Thumbs Up
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Nope.
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PostPosted: 11:57 - 18 Feb 2016    Post subject: Reply with quote

Did a bit more last night. Put on the first few coats of black onto the bottom triple:

http://farm2.staticflickr.com/1540/24479303993_2a42b6dcbb.jpg

Got the swing arm back from the local engineering firm. They did a great job on the threaded collars:

http://farm2.staticflickr.com/1506/25079825446_c5d76e6311.jpg

And they also sorted out the snapped stud in the back. The thread was a little bit buggered so they drilled it deeper and used a bottom tap so it now takes a longer bolt. So long as it works!

http://farm2.staticflickr.com/1475/24479313823_9714b8261b.jpg

I'm going to be dropping all the bits off to the powder coaters tomorrow morning. Excited to get building!
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Fizzer Thou
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PostPosted: 21:34 - 18 Feb 2016    Post subject: Reply with quote

The good thing about the 5PW is that the sub-frame is seperate to the main frame,so fewer were written off.So it is good to see one in reasonable condition Thumbs Up

For some good advice and help with spare parts,have a look see on

http://www.yamahar.co.uk/

I am on there somewhere Dance!
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Nope.
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PostPosted: 22:58 - 18 Feb 2016    Post subject: Reply with quote

Fizzer Thou wrote:
The good thing about the 5PW is that the sub-frame is seperate to the main frame,so fewer were written off.So it is good to see one in reasonable condition Thumbs Up


Thanks! I'm not sure reasonable condition is the right word though Laughing It's made of about 4 different bikes and certainly needs tidying up. Hopefully when I'm done with it it'll be halfway decent Very Happy

Fizzer Thou wrote:

For some good advice and help with spare parts,have a look see on

http://www.yamahar.co.uk/

I am on there somewhere Dance!


Heh heh, check out the projects section and you may just find a thread somewhat similar to this one Wink

Thanks for the support chaps!
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Nope.
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PostPosted: 23:49 - 21 Feb 2016    Post subject: Reply with quote

While the frame, subframe and swing arm are at the powder coaters I thought I'd do a bit more stripping down of the old motor and a bit more painting.

First up I removed one of the coolant pipes, cleaned it up and thought I'd try some VHT Red wrinkle paint on it. Not sure I'm sold just yet...

http://farm2.staticflickr.com/1564/25180132585_6348628017.jpg

I'd also finished lacquering the bottom triple, not sure if it's going to chip or not but it's not too hard to re-paint should that happen:

http://farm2.staticflickr.com/1668/25086897691_d446a794f9.jpg

Got on with stripping down the old motor. Removed the oil pickup:

http://farm2.staticflickr.com/1549/24549445984_544213bfed.jpg

Yeah... Thats not ideal...

http://farm2.staticflickr.com/1659/24553292213_9c957d4a9f.jpg

Neither is that...

Removed the water pump feeds, gearbox selector cover, neutral pickup and crank shaft sensor:

http://farm2.staticflickr.com/1572/24549445364_ff868a7b4a.jpg

Then I removed the cam chain and cam chain sprocket:

http://farm2.staticflickr.com/1525/25180137685_83d163df54.jpg

http://farm2.staticflickr.com/1462/24812429269_2645aa8df8.jpg

Also started cleaning up the sump pan and getting rid of all the clutch bits from it...

http://farm2.staticflickr.com/1578/25153789486_5eb1bc5a51.jpg
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Nope.
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PostPosted: 22:44 - 24 Feb 2016    Post subject: Reply with quote

So, still waiting for the stuff from the powder coaters I got on with a few more bits.

I needed to get the flywheel off the old engine, so I needed an M16/1.5 puller. I didn't have one to hand, so my friend turned me one up at work:

http://farm2.staticflickr.com/1545/24611983444_729a730ede.jpg

It fitted in the thread and everything but I couldn't get enough force on it to get the flywheel to come off because it didn't have a hex head top. I nipped to my friends garage the next day and borrowed his puller set. Used a breaker bar on it and got the flywheel off.

Tonight I got the brake discs off the wheels. I'm intending to replace them at some point but they're looking rather tatty so I cleaned them up, masked them and sprayed them with VHT paint. I know the fronts are anodised as standard but it's chipped quite badly so it doesn't look great. I can't separate the outer disc from the inner because the floating bobbins are press fitted so I can't get them re-anodised easily.

http://farm2.staticflickr.com/1599/25216358326_27793ba197.jpg

http://farm2.staticflickr.com/1620/25124361772_e2bc42ceb1.jpg

http://farm2.staticflickr.com/1577/25124362882_0de882466b.jpg

http://farm2.staticflickr.com/1489/24874958389_9a41272973.jpg

Should have the frame etc. back on friday Very Happy
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Nope.
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PostPosted: 23:19 - 26 Feb 2016    Post subject: Reply with quote

Got the stuff back from the powder coaters:

http://farm2.staticflickr.com/1449/25256296186_64d6ece6bd.jpg

Made a very dodgy tool to do up the swing arm tensioning collet:

http://farm2.staticflickr.com/1598/25189411371_c49670ee66.jpg

Cleaned up all the swing arm fixings and gave the end caps a lick of paint:

http://farm2.staticflickr.com/1514/24914879479_17ef394e0c.jpg

Hopefully tomorrow I can start getting it re-assembled!
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Nope.
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PostPosted: 18:17 - 27 Feb 2016    Post subject: Reply with quote

Started assembling today, got the new swing arm bearings in, bushing back in, caps on, chain guide on, swing arm back in the frame, suspension and links on and the chain adjusters in Very Happy

http://farm2.staticflickr.com/1595/25216556391_b62f7ec947.jpg

http://farm2.staticflickr.com/1507/25216558711_71c5f4073a.jpg
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Nope.
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PostPosted: 09:43 - 29 Feb 2016    Post subject: Reply with quote

Little bit of progress last night when I got back from London.

Got the discs back on the front wheel...

http://farm2.staticflickr.com/1473/25240453902_aa1bb1ddb9.jpg

And the bobbins back on the swing arm

http://farm2.staticflickr.com/1663/24728099974_8f4892420f.jpg

http://farm2.staticflickr.com/1627/25265647281_1118cf58be.jpg
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bladeblaster
Trackday Trickster



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PostPosted: 10:03 - 29 Feb 2016    Post subject: Reply with quote

coming along nicely Thumbs Up
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craigs23
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PostPosted: 20:05 - 29 Feb 2016    Post subject: Reply with quote

Farbeit for me to critique the cosmetics of an 03 R1 (still arguably one of my favourite looking Japanese litre bikes), but think I prefer your gloss black powder coated frame to the original's finish.

Nice work Thumbs Up
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Fizzer Thou
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PostPosted: 19:50 - 01 Mar 2016    Post subject: Reply with quote

Coming along nicely Thumbs Up

As has been said,the gloss black finish is a lot better looking than the original and should be easier to keep clean Dance!
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Nope.
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PostPosted: 22:44 - 18 Jun 2016    Post subject: Reply with quote

Ok, so this went dark for a while as some personal stuff happened and I was kinda not at all motivated to touch this.

Then I went to the Isle of man TT on the Tenere:

http://c2.staticflickr.com/8/7607/27756855825_b1d7b61750.jpg

http://c1.staticflickr.com/8/7340/27478294760_5e506f5e77_c.jpg

And it kinda motivated me to get a move on with this so it's ready for next year! Then I had a little (really little) off last weekend which kept me out of action for a few days with some whiplash and a (still) buggered knee, but I was well enough to start paint stripping the tank. Some of you may have seen my workshop thread where I said I wanted to strip the tank to bare metal, brush it and then lacquer it, but having started stripping it it would appear that it's mostly filler! May need a new tank, but I'm going to sand the filler out and see what damage there is:

http://c5.staticflickr.com/8/7792/27144671204_1754be42ea_c.jpg

I finally got the new bolts I needed for the right hand cylinder head mount in from Yamaha, so the engine is finally in the frame!:

http://c1.staticflickr.com/8/7311/27478294200_9c10df43f1_c.jpg

Hopefully tomorrow I can get it on the forks and wheels!
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Nope.
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PostPosted: 22:43 - 19 Jun 2016    Post subject: Reply with quote

Got the forks in today:

http://c7.staticflickr.com/8/7239/27168409574_faabd324cf_c.jpg

Wanted to get the wheels on but lost a front wheel spacer Evil or Very Mad so I'll have to wait until I can get another one.
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Last edited by Nope. on 11:51 - 20 Jun 2016; edited 1 time in total
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Snowdonia Rider
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PostPosted: 07:55 - 20 Jun 2016    Post subject: Reply with quote

https://youtu.be/HisD_pqlRHQ

Sounds similar Razz
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Nope.
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PostPosted: 11:52 - 20 Jun 2016    Post subject: Reply with quote

under_rated wrote:
https://youtu.be/HisD_pqlRHQ

Sounds similar Razz


I did say it was a rebuild, not a restoration Laughing

The swing arm and wheels are the same!!!! Laughing
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Old Thread Alert!

There is a gap of 253 days between these two posts...

Nope.
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PostPosted: 15:27 - 28 Feb 2017    Post subject: Reply with quote

We'll, I've done a bit more on this since the last update, but not a whole lot!

I turned up some captive front wheel spacers copying some a friend had and got them fitted to the wheels (the wheels are getting painted in a couple of weeks):

https://c1.staticflickr.com/3/2866/32354862563_045b6d769b_z.jpg

https://c1.staticflickr.com/4/3930/33128553506_c3561c62f1_z.jpg

Then I turned a few thou off the rear brake disc to remove the worst of the scoring:

https://c1.staticflickr.com/4/3889/32787706810_a355382bf5_z.jpg

Then I enlisted the help of my dad to get the bike off the floor and the wheels back on:

https://c1.staticflickr.com/1/576/32354811923_021816a013_z.jpg

https://c1.staticflickr.com/4/3689/32354812333_36eb1e6752_z.jpg

Then I bolted the subframe back on:

https://c1.staticflickr.com/1/687/33013599072_37715e6726_z.jpg


And then I went for a Five guys because it was 21:30 and I hadn't eaten yet Very Happy

https://c1.staticflickr.com/4/3830/33170329625_0404857d07_z.jpg
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Nope.
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PostPosted: 22:15 - 28 Feb 2017    Post subject: Reply with quote

Didn't get a massive amount done tonight, only putting in about an hour and a half a night at the moment, but still it's progress!

Tonight I machined some AIS plugs and installed them in the (already tapped to M10) head:

https://c1.staticflickr.com/1/617/33020121022_9c949db9ba_z.jpg

https://c1.staticflickr.com/1/646/33048925611_745fae225a_z.jpg

https://c1.staticflickr.com/1/720/33176620985_d097cb0d33_z.jpg

Hopefully they'll work as intended, don't see why they wouldn't!
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chris-red
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PostPosted: 17:05 - 02 Mar 2017    Post subject: Reply with quote

Assuming AIS is some kind of Secondary Air thing. It might be worth wrapping those plugs in PTFE tape.
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Nope.
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PostPosted: 18:51 - 02 Mar 2017    Post subject: Reply with quote

chris-red wrote:
Assuming AIS is some kind of Secondary Air thing. It might be worth wrapping those plugs in PTFE tape.


Not a bad shout, but a bit concerned about putting PTFE tape in the head that close to the exhaust port. What sort of temperature can it withstand?
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