From auctions to racebike - a build story

[Marshy]

I've recently built a new racebike for the 2013 season (well, two actually - the wet bike will feature later), and I thought it might be interesting to show the process from buying a wreck at auction to turning it into a racebike.

Won the auction! Paid waaaay too much, but really wanted the bike because it was the right year model/compliance plate for St George's clubsport 600 class, while still hopefully being semi-competitive against the latest machinery. It also looked virtually undamaged in the photos (this was a Pickles new e-salvage auction where you couldn't view the bikes in person). Looks perfect in the photos, low kays so hopefully the engine is fresh, although it'll need a new stator cover.

Get the bike home and give it a quick wash. Looks good!



So let's replace that alternator cover and see how she runs! Uh-oh.........



That's not good.....







By now I've realised that the stator casing is a single piece of alloy that includes the entire engine block. I get some advice that tells me it's a $2k fix, and I'd be probably better off getting a whole replacement engine. I'm just gonna slink off and have a little cry. Beware of buying at auction, people!!!

[Marshy]

The next day, I get some different advice, and I like this new advice muuuuch more. It might be fixable, and for not too much coin too!

Awesomely, it comes back looking great!! The acid test will be an outing on track, but so far it is looking good.



Honestly, if I hadn't told you, you'd never know....

K-tech suspension has been ordered, and the rear has arrived, so let's at least get some bling happening, to make ourselves feel better!






Uh-oh...... I'm fairly sure that both dogbones are supposed to be flat and straight.






A quick trip to Metros and we are back on track! The shock goes in.

[Marshy]

With a very tight timeframe for this build, the aim was to get the bike on track asap to check it ran ok. There's a few things to take care of first:

Fit an Annitori quickshifter from Superbike Source - http://superbikesource.com.au/produc...fter-Gen2.html








Take care of some lockwiring:









Fit clipons - http://superbikesource.com.au/produc...p%252dons.html





Fit a fan switch. 'How to' here (and use the switch in the how to, not the one in this pic!): http://tarmactalk.com/forum/showthre...-to-a-racebike





Fit rearsets:





Slicks fitted too. Ready for its first track test!

[Marshy]

Well the first test day was a pretty big FAIL!!! The bike handled like crap, and I chewed up a brand new $440 rear tyre in 2 sessions. This is how it looked after 2 sessions. It got muuuuuch worse very quickly after that!! It looks like a rebound issue.....





Just to give me something else to be upset about, the bike is also leaking oil - not a lot, but enough to be of concern. And not where the repair was - that is holding up perfectly!! The only problem is that the oil seems to be magically appearing at the very bottom of the sump, but with no obvious path to get there. Hmmmmm, call it a day, I reckon.

Took the exhaust off to have a proper look for the new oil leak, and discovered a crack in the sump!! Hidden by the exhaust, but obvious once the exhaust was removed.







More repairs. Hey, ever wondered what it looks like underneath the engine?? Me too!

[Marshy]

With the bike in pieces, it's a good opportunity to keep fitting new bits! Gratuitous naked photo:





On goes the Bazzaz:





New plugs are always a good idea:





Poor man's smog block-off plates.... (proper ones are in the mail)





Replaced that earlier plastic fan switch that broke on first use:





Woodcraft frame sliders:

[pensioner rates]

Enjoying the post Nick ... Bugger having the extra repair work on the motor, looks like the stator cover took a good old wack although the damage didn’t look too bad from the original picture.
Yes always good to change the plugs I have heard that some plugs give a gain in horsepower however I believe that its more about stoping loss of the original horsepower, plugs do go off and before they get noticeable miss the 4 hp loss is easy to achieve. I notice the thread seems to have some carbon build-up so it is exposed in the head you wouldn’t want to leave them in too long or taking them out would root the threads in the head .I wonder how often that’s the case.
What’s the go with the shock, is it not following the tar and bouncing causing that guess you changed the settings so is it a stack rebuild inside?
Nick have you done any tests on laptimes with the quick shifter and without... any solid results like 2 seconds or would it be greater than that for eastern creek lol I am looking for a miricle minute saving.
Cheers Chris

[chubb]

That's been a very interesting read.

[Marshy]

There's more to come!! It's not finished yet.... Subscribe to the thread for more updates. Tomorrow will see another big update.

[Marshy]

The sump is quickly fixed and back on the bike. A BMC air filter goes in too. Then I got rid of the Exup servo motor, replacing it with a 12 O'clock labs eliminator. It looks much cleaner back here without the big servo!





On goes the uber-trick Over titanium full system. I've always been a fan of Over exhausts:





Radiator guard might save the day sometime, so on it goes:





A steering damper is a necessity on an R6:





New gearing is next:








Yuck, greasy!!

[Marshy]

While I think of it, here's how to stop the front plastic air funnel falling out all the time. I love cable ties!! Is there anything they can't fix? Actually yes, what cable ties can't fix, duct tape takes care of!!





More lockwiring needed to complete the job:

















Speaking of the radiator, must empty out the coolant!!





Don't forget the overflow bottle.....





Next, the front end gets sorted!! Stay tuned.

[Marshy]

The bike had handled horribly and chewed a rear tyre in its first test day, so it was time to sort out the bouncy bits. It turns out that for some unknown and mysterious reason, the brand new rear shock had somehow shipped with virtually no working rebound damping (hence the rebound tear of the rear tyre). Also the spring was way too soft, so a much heavier spring was fitted. And with the rebound valving more than doubled (after 3 or 4 rebuilds, each time putting in the bike, bouncing it and taking it out again), finally the rear is sorted!!

Next the front cartridges are fitted:










That takes care of the suspension. Now to stop the bike! A Brembo RCS master cylinder and HEL braided lines (in fetching blue) go on, along with Vesrah SRJL pads. Although I've always maintained that brakes aren't good for racing - they only slow you down! Sorry, that's a Dad joke.









Speaking of trick brake bits, I've always wanted to have the HRC type rear brake tube, but haven't bothered - until now!!






A shark fin goes on too, just to complete the safety requirements package....






And some Tech Spec tank pads:





Nearly done!! Just the electronics and bodywork to go...... Will post that soon.

[Lets Torque]

Nice work...

Dont know about the OHS on the grinder and thongs???

[Marshy]

Don't worry mate - they're WorkCover approved safety-thongs. Safe as houses.

Although my helper in the thongs saw the photos on here and reckoned it looked bad too. But seeing as it wasn't me, it's all good

[Marshy]

I reckon I'm gonna need to know a few things when I'm piloting this weapon, so the XT Racing lap timer goes on next:




Followed by the Starlane gear indicator:




Both together look cool:



And a quick access point for programming the Bazzaz, without having to remove anything:





Some decals for the bodywork:

[windy]

Looking good mate. This is a great read. I really like that lap timer. Might have to see if I can find me one of them or something similar..

[Marshy]

Looking good mate. This is a great read. I really like that lap timer. Might have to see if I can find me one of them or something similar..

Thanks mate

That lap timer I bought locally because I heard they were awesome, and I loved it so much I'm now a dealer for them in Oz.

[windy]

Thanks mate

That lap timer I bought locally because I heard they were awesome, and I loved it so much I'm now a dealer for them in Oz.

Awesome.. Roughly what are they worth? And how hard are they to install? Will be putting this on the shopping list

[fitzy]

awesome write up mate .. some nice shiny parts in there makes me wanna get my ass into get and get my gsxr ready. ..is there more to come?

[Marshy]

Yep, there's more! Checking the geometry with Computrack, fitting some YEC goodies, and a couple of other minor things. Subscribe to the thread

[shippy__]

is that it ? lost interest?

[Marshy]

D'oh!! Got on to other builds.... Although I've still got the additional photos somewhere, so I'll finish this off in the next few days