|
Author |
Message |
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
Posted: 01:30 - 12 Feb 2016 Post subject: 2003 R1 5PW Rebuild (Pic heavy) |
|
|
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:
https://farm1.staticflickr.com/617/22669217769_2e096639a0_z.jpg
https://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 :
https://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!):
https://farm1.staticflickr.com/773/22643145457_fd15001328_z.jpg
https://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!
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
https://farm1.staticflickr.com/732/22440296683_65b02bfe35_z.jpg
I also vinyl wrapped the tail:
https://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:
https://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:
https://farm1.staticflickr.com/610/23047907972_0c1e2ce094_z.jpg
https://farm6.staticflickr.com/5730/23061501535_534cb2d145_z.jpg
The top end was in remarkably good nick:
https://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:
https://farm6.staticflickr.com/5628/22440298903_072ab4d199_z.jpg
https://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:
https://farm6.staticflickr.com/5831/22641977648_2a901c0b86_z.jpg
https://farm1.staticflickr.com/564/22439173983_aca44dfeab_z.jpg
The clutch has completely shattered. Brilliant.
https://farm1.staticflickr.com/737/22438715424_2e3b21cc97_z.jpg
https://farm6.staticflickr.com/5812/22669223519_614878f663_z.jpg
https://farm6.staticflickr.com/5710/23047910002_0349c2ab32_z.jpg
https://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 :
https://farm1.staticflickr.com/767/22642024897_53717ffa42_z.jpg
I set about stripping her down:
https://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:
https://farm1.staticflickr.com/691/22641977888_104870b7a9_z.jpg
https://farm6.staticflickr.com/5677/23136116441_fd942a91d4_z_d.jpg
https://farm6.staticflickr.com/5639/22503378703_43ca005c42_z_d.jpg
Also painted the side stand:
https://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):
https://farm6.staticflickr.com/5639/22503378703_0275446438_k.jpg
https://farm2.staticflickr.com/1675/24931391766_7b0555d4ef_k.jpg
Then I got the shock out:
https://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!
https://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:
https://farm2.staticflickr.com/1711/24598419829_e9f4a1ff42_h.jpg
https://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 . 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 |
|
Back to top |
|
You must be logged in to rate posts |
|
|
..... |
This post is not being displayed .
|
..... Quote Me Happy
Joined: 15 Jan 2005 Karma :
|
Posted: 09:13 - 12 Feb 2016 Post subject: |
|
|
Good stuff |
|
Back to top |
|
You must be logged in to rate posts |
|
|
ride_to_die |
This post is not being displayed .
|
ride_to_die Crazy Courier
Joined: 13 Nov 2005 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
bladeblaster |
This post is not being displayed .
|
bladeblaster Trackday Trickster
Joined: 19 Jan 2015 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
c_dug |
This post is not being displayed .
|
c_dug Super Spammer
Joined: 04 Sep 2007 Karma :
|
Posted: 19:10 - 16 Feb 2016 Post subject: |
|
|
Cool stuff ____________________ I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock. |
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Fizzer Thou |
This post is not being displayed .
|
Fizzer Thou World Chat Champion
Joined: 06 Aug 2011 Karma :
|
Posted: 22:34 - 18 Feb 2016 Post subject: |
|
|
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
For some good advice and help with spare parts,have a look see on
https://www.yamahar.co.uk/
I am on there somewhere ____________________ Just talk bikes.What else is there?
Always have a 'Plan B' |
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
Posted: 23:58 - 18 Feb 2016 Post subject: |
|
|
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
Posted: 10:43 - 29 Feb 2016 Post subject: |
|
|
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
bladeblaster |
This post is not being displayed .
|
bladeblaster Trackday Trickster
Joined: 19 Jan 2015 Karma :
|
Posted: 11:03 - 29 Feb 2016 Post subject: |
|
|
coming along nicely |
|
Back to top |
|
You must be logged in to rate posts |
|
|
craigs23 |
This post is not being displayed .
|
craigs23 Mr Muscle
Joined: 08 Jun 2005 Karma :
|
Posted: 21:05 - 29 Feb 2016 Post subject: |
|
|
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 |
|
Back to top |
|
You must be logged in to rate posts |
|
|
Fizzer Thou |
This post is not being displayed .
|
Fizzer Thou World Chat Champion
Joined: 06 Aug 2011 Karma :
|
Posted: 20:50 - 01 Mar 2016 Post subject: |
|
|
Coming along nicely
As has been said,the gloss black finish is a lot better looking than the original and should be easier to keep clean ____________________ Just talk bikes.What else is there?
Always have a 'Plan B' |
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
Posted: 23:44 - 18 Jun 2016 Post subject: |
|
|
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:
https://c2.staticflickr.com/8/7607/27756855825_b1d7b61750.jpg
https://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:
https://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!:
https://c1.staticflickr.com/8/7311/27478294200_9c10df43f1_c.jpg
Hopefully tomorrow I can get it on the forks and wheels! ____________________ 2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build) |
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
Posted: 23:43 - 19 Jun 2016 Post subject: |
|
|
Got the forks in today:
https://c7.staticflickr.com/8/7239/27168409574_faabd324cf_c.jpg
Wanted to get the wheels on but lost a front wheel spacer so I'll have to wait until I can get another one. ____________________ 2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)
Last edited by Nope. on 12:51 - 20 Jun 2016; edited 1 time in total |
|
Back to top |
|
You must be logged in to rate posts |
|
|
Snowdonia Rider |
This post is not being displayed .
|
Snowdonia Rider World Chat Champion
Joined: 17 Oct 2014 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Old Thread Alert!
There is a gap of 253 days between these two posts... |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
chris-red |
This post is not being displayed .
|
chris-red Have you considered a TDM?
Joined: 21 Sep 2005 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Nope. |
This post is not being displayed .
|
Nope. World Chat Champion
Joined: 17 Feb 2011 Karma :
|
|
Back to top |
|
You must be logged in to rate posts |
|
|
Old Thread Alert!
The last post was made 7 years, 101 days ago. Instead of replying here, would creating a new thread be more useful? |
|
|
|