I have been working on this project for a while now , collecting bits off ebay when they come up cheap and hopefully it will be ready for my 1st race meet with st george mc club in November . I had done most things with the cbr but one that i hadnt done was a complete engine rebuild so i was keen to see how it was put together . I bought a very cheap bike from the auction that needed a new motor as the one in it had the engine casing damaged where the oil pressure line is . I bought a spare crankcase from the states and started the strip down.
top cover removed showing cams
camshafts removed
Rhs engine showing clutch and starter clutch removed
Cylinder head removed
Underneath the motor , when the sumps removed showing the oil pump. Having the motor attatched to an engine stand really helps when doing any work on the motor.
Oil pump removed .
Lower casing removed.
Crank and gears.
Now to assemble the bits into the newish casings. Cleaned up the bores with flexhone.
Pistons fitted with new rings.
New bearings for the crank and conrods.
Casings back together .
I didn't remove the valves or do anything else to the head , apart from a new head gasket and just checked the clearances when i put the cams back in , all were ok .
Frame has been blasted cleaned and powdercoated to make it look new again as the previous owner had painted bits of it a terrible orange colour .
Nice and easy does it . Good to have a few axle stands to hold everything when lowering the frame onto the motor.
Had to fit the new throttle cables before the airbox goes on , new motion pro set up with interchangeable throttle discs . Fitting the airbox has to be the worst job so far , still havent found the best way yet to make it easy. Wiring harness and swing arm fitted .
New Akrapovic headers .
Subframe and exhaust finished off . Started to fit the new cooling hoses.
Got a few more hours on the biketoday. Radiator fitted , air intake and dash , filled with some wet stuff , no leaks
checked the oil ... connected battery and gave her a spark of life ...... She is alive...
Runs smooth once the fuel got into her .
Fitted up the wheel .. need some more rubber and put the calipers on and bled the new brembo. Its a tight fit getting the master cylinder , kill switch and the throttle on the bar.
Now to do some tidying up and finishing off some bits and pieces ... might even get to come out to play on the 27th. Not sure what the best way to go with the power commander . I have a pc5 and an auto tune for it with a race air filter , maybe put the standard air filter in for now and take it easy without the pc5?
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