2006 R1 buld - long time between drinks ;)

[LKC73]

Hello Lads,
I'm back again, and with another new build underway.
I got offered a 2006 R1 that had been crashed with some engine damage. The first thing I did was a check of its numbers as I was told it wasn't a write off.
As per the sellers words, it has only a cancelled rego. So the purchase was made and collections done. Here is the build, it will be some time due to parts needed but it will get there. Again, my theme will be German style again, but with sharper lines and more aggressive shape.
First up was the pic up. This is how it arrived home.
http://i.imgur.com/rbmVU19.jpg
The pull down.
http://i.imgur.com/cxhwBYx.jpg
Some wires got cut in the crash so fixed them up
http://i.imgur.com/1OBXP1C.jpg
Then pulled the engine out to do repairs (swap cases)
http://i.imgur.com/Ifyp9VK.jpg

The Damaged lower and upper engine case.
http://i.imgur.com/rItnwLc.jpg
That's all for now, but will add more to the build as I go on. It wont be as fast as my 7/11 6 years ago, but within 8 to 10 months it will be what I want it to be. Hope you all enjoy the build.

[ozzy1100]

Insert mister burns.... excellent...

[wackyrider]

Good to see you back Luke

[Gix11]

Nice one Luke. Keep it coming.

[Simo74]

Quality, cant wait to see this progress.

[BANDITROD]

this will be good

[LKC73]

So I've been chipping away and have now got the engine stripped down to bare block which isn't any good.
I will be collecting parts while I wait for the new block (Case's) to arrive. The service manual calls out for replacing the conrod bolts, which I will do just to be safe. Last thing I want is one of them to fail and destroy all the hard work.
http://i.imgur.com/H3BJUcX.jpg
http://i.imgur.com/QQLXkyO.jpg

[geesexar]

good stuff Luke keep the updates comibn

[Gix11]

Yep, what Wayne said.

[wackyrider]

Taking it easy? You've done more on this in a week then I have done on the CB750 in the last 18 months

[TillerRider]

Lol he doesn't really know the meaning of "taking it easy" really!

[LKC73]

Friday I got a nice big box delivered to my work. Open it up and the cases have arrived.
So I get home check them over and they look fine enough to use.

Saturday I had started installing the gearbox and realised I have to wait for the ConRod bolts before I go to much further.
Pic with gearbox install.
http://i.imgur.com/FdAlGkD.jpg

[LKC73]

Got the cylinder and head bolted back down now.
http://i.imgur.com/7Syx3BH.jpg

All conrods connected to the crank now and all the bottom case fitted and set in. Bottom end accessories refitted (not pictured)
http://i.imgur.com/KLowfPn.jpg
http://i.imgur.com/libg0nG.jpg
Flipped back on the sump and time to set cams timing and check clave clearances.
Hopefully the engine will be back in its frame sometime next week.

[wackyrider]

Taking it slow hey?

[TillerRider]

Taking it slow hey?
He doesn't know the meaning of "slow" lol

[LKC73]

I've only been working on it a few hour a night. Just happens that every time I need to work on it the parts I need come in the post. So this keeps me motivated. I didn't get any pic's from last nights work, but all the bottom end parts have been fitted.
I flipped it over and installed the cams set the timing and checked clearances.
Engine is now ready to refit into the frame woot! :cool:

[wackyrider]

Well, we just picked up another bike too. An 04 R1 for the Mrs as the new project

[LKC73]

Well, we just picked up another bike too. An 04 R1 for the Mrs as the new project
Same build as mine one, they ran from 04 to 06 with the 5 valve head and then on they switched back to 4 valve head in 07.
Nice one Jules, look forward to the build thread of yours ;)

[wackyrider]

See now mine is gonna be slow. Have 3 bikes and a car for sale at the moment, haha. Need to make some room

[LKC73]

Progress over the weekend seen the motor back into the bike and all needed little parts back on.
The bike is now just waiting on some other parts to arrive before it can be started up again.
Maybe a few weeks as some are coming from Japan. One pissy little oil pipe will take up to 10 days to arrive.
Anyhoo, pic's!
http://i.imgur.com/nM2FzBd.jpg
http://i.imgur.com/Yf4ig7O.jpg

[The Phantom]

Absolutely belting along with this build - nice work.

[LKC73]

Just a bit more done towards getting this thing running again.

I bought 09 FZ1 throttle cables as they are longer than stock R1 units. This will suite the risers and bar set up we all want.
http://i.imgur.com/ECPBrUN.jpg

Refitted the throttle bodies after the cables attached. Airbox back in place.
http://i.imgur.com/LAnSTHd.jpg

While mucking around, I removed the bars and cleared out the forks for new risers to be installed.
I'm planning on using low rise fat bars for this build.
http://i.imgur.com/unRW5Wz.jpg

Top part of the bike is just about ready to go. Radiator next and new discs and some lines and we are almost ready for rego.
http://i.imgur.com/Y8jVMwp.jpg

[Bob]

Coming along great bud

[wackyrider]

Need to start pulling the broken parts off the R1 this weekend and assess where we are on it but should be mostly all good

[LKC73]

Jules, as long as it isn't as bad as mine was you'll be laughing. I'm still waiting on more parts to arrive and my next pay to order more just to get this thing running. But it will get there.

[LKC73]

Small update, radiator arrived and all fitted up. Just waiting on a few more parts still!
I have the header pipe back on as well and small bits and shits.

http://i.imgur.com/0tAGXIe.jpg

http://i.imgur.com/iLWQwkA.jpg

[wackyrider]

What headlight are you running on it?

Keeping the stock tail?

[LKC73]

What headlight are you running on it?

Keeping the stock tail?

I actually have a wave light like the 7/11 and will be ordering a mask soon.
The tail will be changed but only after rego is on the bike.


Parts I do need is a Right foot bracket, indicator's for the front bars and risers and a front disc.

[LKC73]

So I have all the stuff I need now to kick this thing in the guts and see if it'll run.
I also got my bars and risers so they'll be installed over the weekend as well.
If I'm game, I'll video the first fire-up of the R1 after I prime it.

[LKC73]

So last night I installed the risers and bars. I also got my new headlight and will make the mount for that.
In the pictures you can see an idea for the dash and where I am thinking of mounting it.
I'll be making a fibreglass bolt on one to see how I like it. Sitting on the bike it gives great view of the dash there.

http://i.imgur.com/P84iTgO.jpg

http://i.imgur.com/G0hfoTB.jpg

http://i.imgur.com/A9vaK5N.jpg

http://i.imgur.com/63HCAah.jpg

[LKC73]

So after I have primed it and built up some oil pressure, I installed the pugs and filled it with water and fired it up!
HOORAY it started, those of you on facebook would have seen it live last night.

Sad news is, I had to replace 2 water hose's and repair a water pipe and replace one of the water "O" rings.
But besides this, It started with very little effort, showed no faults on the dash board and idled super some.

Next I set out to put the switch blocks on and sort out some wiring routes.

http://i.imgur.com/A9vaK5N.jpg

http://i.imgur.com/kDRu50p.jpg

http://i.imgur.com/bWLZdte.jpg

[wackyrider]

If you end up mounting the gauge ont he tank, I might need to have a chat with you...

[ozzy1100]

I too think the gauge on the tank is a hot idea, it cleans up the bars for that striped street monster look
be cool if you cut down the factory housing and move the read outs in relation to the tach, to be honest
it wouldn't be worth the effort just thought it was a cool idea with a custom bezel
whole build is a cool bike

[LKC73]

Jule's, It will be there mate, and I will be making a mould to install as a bolt on unit. If your interested in this idea, Message me if your keen.

[LKC73]

So only been doing little things for the time being. Christmas around the corner and other things to pay for this has now slowed down. I have a few things to work on while I wait.


Indicator brackets made, only raw in this picture but they will be tidier and painted black.
http://i.imgur.com/tNpzkWf.jpg
http://i.imgur.com/rbkuUUk.jpg

Again with the headlight bracket in raw and yet to be painted and maybe narrowed a bit.
http://i.imgur.com/aWOO4cl.jpg
I am currently working on the gauge mount for the tank, pictures to come later if it works :cool:

[The Phantom]

Looking good.

That casting seam around the lower tripleclamp looks arse - pull the front end off and buff the seam off the lower, it makes it look liks a billet tripleclamp. Worth doing on a fighter because the triples are out there on display.

[LKC73]

Looking good.

That casting seam around the lower tripleclamp looks arse - pull the front end off and buff the seam off the lower, it makes it look liks a billet tripleclamp. Worth doing on a fighter because the triples are out there on display.

Yep my thoughts too, was going to paint it black to hide it even more. Just setting everything up for now so will pull it down once its sorted.

[The Phantom]

Awesome :)

[LKC73]

A few weeks on and I have carried out some more small works.
Removed the bottom triple clamp and smoothed all seem lines off it and gave it a satin black finish.
http://i.imgur.com/zbw7xbw.jpg
http://i.imgur.com/iwJsQ4A.jpg

I also kept going with the tank dash mount. Its been glassed and all wires are run up through the tank cover.
I just need to do a final filler to fill some low points and then I'll paint it black along with the tank cover.
http://i.imgur.com/L6WQziL.jpg
http://i.imgur.com/ZtVVAT9.jpg

I have also got a new rearsets but didn't get around to setting them up.

[Gix11]

Cool! I'm liking it.

[chinski]

sweet work on dash mate, and lower triple came up well, was going to try to paint mine in place but might be worth taking it right off to get rid of seam after seeing this

[JimZXR]

That gauge mount is awesome. How is it for visibility?

[LKC73]

That gauge mount is awesome. How is it for visibility?

Just from sitting on the bike its good. But yet to see how well it is on road yet and that will have to wait until it see's rego.
Cheers for the comments though.

[LKC73]

So moving along with things slowly I have been working on the dash mount for the tank.
Its not final finish as yet, but was over the sanding and filling so it will do for now until I get the tail and mask and belly pan work started. Oh and it has rear sets now to.
http://i.imgur.com/wpPVi9Z.jpg
http://i.imgur.com/uFxwIg2.jpg

http://i.imgur.com/I3Rb5an.jpg

[BOBBY]

From here that looks nearly like a factory fitted mount.

[Gix11]

Shit hot mate!

[wackyrider]

What cables have you had to extend and what has remained factory mate?

[LKC73]

What cables have you had to extend and what has remained factory mate?

Jules, I have 09 FZ1 throttle, everything else is factory. The clutch cable to my surprise was long enough.
The switch block on the throttle had a doubled up cable which was handy. The left side was just brought forward and runs on the outside of the forks and fixed with a cable tie at this point.

[LKC73]

I got a great Christmas prezzy from my girl. And this will be attached after rego but you get the idea of how things will shape up.
I was very please though, as I jagged the headlight bracket to the mask location. It is near perfect for it. Forgot to add, Mirrors turned up just before Christmas so there installed as well.
http://i.imgur.com/8gQ1tHE.jpg
http://i.imgur.com/zrXrwBG.jpg
http://i.imgur.com/Bng7SxV.jpg
http://i.imgur.com/gnzTDWA.jpg

The front guard from gumtree, its not what I want on the finished bike but its there to pass rego. Thanks to Jason for giving it a lick of paint though. All that remains for rego is the brake lines, which I'll order after a holiday. Then its off for Blue Slip and fingers crossed rego.
http://i.imgur.com/YjnmY5K.jpg

[Bob]

Awsome stuff mate

[JimZXR]

Killer mask

[LKC73]

I have finally been able to get back working on this beast. And she is now ready for NSW Blue slip.
New braided lines from Hel Australia arrived late last week and The new Brake pot and bracket installed and all bled up. Thanks to Yella for the replacement R1 tail, it is now looking cleaner.

I am currently working on the mounts for the mask but this isn't required for blue slip.
http://i.imgur.com/FSGkGA0.jpg
http://i.imgur.com/Gqk4dZj.jpg

Stage 2 will be after rego is done, which will be reworked tail, new pipes and belly pan, new front guard with a full paint job.
I'll be keeping this updated along the way still.

[Gix11]

Fuck you work fast Luke! Nice one mate.

[Weaselman]

Fuck. That's awesome.

[chinski]

stage 1 is sweet already mate stage 2 will be something !! any dramas with rego ?

[BOBBY]

Whs^^^

[LKC73]

stage 1 is sweet already mate stage 2 will be something !! any dramas with rego ?

I have yet to book it in for the blue slip. I have to save some money for the Green slip as they cost $650 there abouts in NSW.
I'll let you know if there is any dramas, but being mostly stock bar headlight and bars I really done see and issue.

The only thing I have to make sure is that the new rego papers have the new engine number on it.

[BOBBY]

$650 is steep man. Pretty sure my Cbr is $350 through qbe. Maybe cause it's not 1000cc.

[Goodtime]

My green slip for my 893cc 900RR is steep as well. I am up for a new one soon, so I will definitely hit QBE for a quote. I use Carriers Insurance Brokers usually and they often find me the best deal.

[LKC73]

My green slip for my 893cc 900RR is steep as well. I am up for a new one soon, so I will definitely hit QBE for a quote. I use Carriers Insurance Brokers usually and they often find me the best deal.

Due to this bike having what is called 1st time rego, they hit you up a bit, but when I got an online quote through the green slip check they all pretty much come in nothing under $600. Unfortunately it is what it is and I want this bike on the road so will deal with it.

[LKC73]

I have been booked in for a Blue Slip inspection this coming Monday. Woot fingers crossed by Tuesday arvo I'll have some brilliant news for you all.

[LKC73]

So I gave my mask a paint job today. Its only satin black and red to see how it would look.
Easy to remove for blue slip and the headlight remains.
http://i.imgur.com/uXXf6sF.jpg
http://i.imgur.com/vErbvbZ.jpg

[The Phantom]

That looks awesome

[Gix11]

That does look good mate!

[Bob]

Good stuff mate. Looks Ace.

[chinski]

fuck yeah mask is awesome in those colors, bike looks good out in the natural light too

[Simo74]

loving the look of this one, really nice job.

[wackyrider]

Looking great mate. Love the mask

[LKC73]

So no blue slip yet, had no trailer to take it where it needed to go. I've now got a loan trailer and will be taking it in on my next RDO (Monday week).

[chinski]

So no blue slip yet, had no trailer to take it where it needed to go. I've now got a loan trailer and will be taking it in on my next RDO (Monday week).

Ah man i bet you're hanging to go for a ride on it !! are you going to ride it as is for a bit before the next stage of fightering ?

[LKC73]

Yeah I am stinging to get it on the road. It will stay like it is for a while until I collect the parts I want to finish off the rest of the work. The tail will take the longest time due to being modified between the stock R1 and the fighter tail I have.

[LKC73]

So while saving some coin to get the bike rego I got another delivery from a great bloke here.
Arrived last week and did a trial fit to see what's needed to attach it.

http://i.imgur.com/4avK63s.jpg

http://i.imgur.com/QnRLIWC.jpg

http://i.imgur.com/OGgO2Mi.jpg

I'll make some brackets and give it a bit of paint. I may modify it a little just to suite the bike a little better.
Another attempt at getting actually to the Mechanic to have blue slip will be done on Monday again.

[Gix11]

Dan?

It's like your in the starting blocks just twitching to get going....

[LKC73]

Dan? (Yeah it was his)

It's like your in the starting blocks just twitching to get going....

Wait until I get my tail section started Si :cool:

[chinski]

Wait until I get my tail section started Si :cool:

still running undertail pipes or changing ? or is that top secret haha ? loving watching this come along ! R1's are the coolest :P

[LKC73]

still running undertail pipes or changing ? or is that top secret haha ? loving watching this come along ! R1's are the coolest :P

No secret, I'll be running the undertail pipes just a lot shorter than what they are. I'm still awaiting on the other half of the tail to arrive yet. But I cant get to ahead of myself just yet, Blue slip process still to get through.

[chinski]

yeah cool mate tail swap & undertails sounds interesting ! nice !

[LKC73]

So I've just been tinkering around the font guard and made brackets and did some reshaping of the rear mount.
Gave it a quick squirt of black and its done.
Grabbed some pro-bolts as well in red to tidy the colours up.

http://i.imgur.com/BUNNta1.jpg

http://i.imgur.com/8pQS9sa.jpg

Due to some unexpected bills, I'm holding off the blue slip until savings is back up again.
But it will get there very soon. I am a bit bummed but I can wait.

[LKC73]

Also looking at the pictures and seeing other R1 post with polished exhaust pipes I'm thinking I should follow this attention to detail and give my exhaust and good clean up.

[chinski]

Also looking at the pictures and seeing other R1 post with polished exhaust pipes I'm thinking I should follow this attention to detail and give my exhaust and good clean up.

i don't think you'll be disappointed with the results of polishing your exhaust, it might be possible to use some sort of polishing head on a die grinder or something to speed up the process ? it took me about 6 hours of polishing by hand to do mine but still worth it i reckon, very cheap way to add a nice feature to bike, just the varying grades of wet'n'dry & finished with autosol is all i used.

bummer about the blue slip mate, bike is looking better & better all the time though !

[JimZXR]

Fuck yes that bike looks sick!

Watching this build closely!

[LKC73]

I've gone a bought a belly pan for the R1 and made brackets and fitted it up. After I made sure it was all good to go gave it a quick paint job. I had also taken the headers off the bike and gave them a good clean. Seeing as they are titanium and not stainless I can gave them a hit with a scotch brite pad instead of a full polish.
I have some Overtime at work coming up so that will see this thing get rego. Then after that it will be parts for the rear end transformation.
pic's below.

http://i.imgur.com/WbioqkM.jpg

http://i.imgur.com/68vtbLJ.jpg

http://i.imgur.com/YJgQwCh.jpg

http://i.imgur.com/MlLjJnB.jpg

http://i.imgur.com/ml15IyM.jpg

http://i.imgur.com/ekwU2V0.jpg

http://i.imgur.com/32DOiRY.jpg

http://i.imgur.com/EfIKt4j.jpg

http://i.imgur.com/eUvue3Y.jpg

[chinski]

Headers look awesome like that mate, the look of your bellypan ties in so nice with the front fender & your mask & they way you added the red highlights, fucken loving your bike more & more every time you post an update !!!! must be so pumped for rego & riding !

[K6Thou]

I've been following on FB and only recently poked my head back in here due to tech issues my end.

This is really looking the business Luke, oh and the guard has been through several owners from here, shadow zone, el hefty and then myself.

Glad it's found its final custodian.

[LKC73]

I've been following on FB and only recently poked my head back in here due to tech issues my end.

This is really looking the business Luke, oh and the guard has been through several owners from here, shadow zone, el hefty and then myself.

Glad it's found its final custodian.

Cheers mate, didn't really know the many hands that guard has been through. But Dan sure was happy to part with it. Yes it has gone to its final custodian, where hopefully it will remain.
I still have more to come, pipes, reworked tail section and of course before all that, rego. But it will get there.

[K6Thou]

Well you helped me out with that alternator........ ;)

[LKC73]

I've been playing with the idea of the tail and working on how and what way I want to go with this beast.
So what I have done is come up with the idea of using a standard front 1/2 of a fibreglass race tail to use the standard seat, and the rear of the fighter tail I have gotten for Xmas of my girl. The other thread about the Delkavik pipes also is incorporated into this idea which is why I asked about them.
Anyway, I have made a very ruff photo chop of that idea.
I am looking for a race tail but most of them sell the race tails without the use of standard seat. If that's not all, the undertray on others is attached as a complete unit. But here is the picture of the tail I have and the idea I have for it. I know its not black, but it gives me a ruff idea of where I want to take this.

http://i291.photobucket.com/albums/ll290/DRA93N/2006%20R1%20fighter/Option_zpshtt1gxnx.jpg (http://s291.photobucket.com/user/DRA93N/media/2006%20R1%20fighter/Option_zpshtt1gxnx.jpg.html)
http://i291.photobucket.com/albums/ll290/DRA93N/2006%20R1%20fighter/Tail1_zpskftnwwsi.jpg (http://s291.photobucket.com/user/DRA93N/media/2006%20R1%20fighter/Tail1_zpskftnwwsi.jpg.html)

[The Phantom]

Personally not a fan of the German style kicked up tail, but that design actually doesn't look too bad at all. I'd like to see a more developed photoshop of it (man it's really time I learned how to drive Photoshop myself)

[LKC73]

I'd like to see a more developed photoshop of it (man it's really time I learned how to drive Photoshop myself)
Same here, I would do a proper render with colour and all. I have a dude I could sent it off to which is what I did last bike build.

[chinski]

fuck yeah ! i reckon that tail will look good with the short little pipes, much neater & smaller than standard tail

[LKC73]

Good news folks, its passed the blue slip! In the next couple of days I'll be in the RMS getting the rego sorted out!
Got to make sure the transfer and engine numbers are done correctly at the RMS hence why I have to go in myself.

I took it for a quick test run a few times to get the feel of it. Holy shit its got grunt, stops well and feels super smooth.
This thing is very nice to ride so far. Bigger test rides to come yet (with rego).

Oh so very close!

[chinski]

if you're as excited as i was for first ride then i know how fucken stoked you are right now haha !!

awesome stuff !

[Gix11]

Great news Luke. Cheers mate.

[LKC73]

As of today, the R1 lives and is now registered! When I get home I'll be putting its new plate on and getting it out there!
Couldn't be happier right now! No issues with the engine number change even being a USA import block.
FUCK YEAH!!!!

[wackyrider]

Sweet. Coming to AFR?? :D

[LKC73]

Sweet. Coming to AFR?? :D

Not now, cant afford to after dropping $1100.00 on the R1 to have it registered.
2 weeks away and next pay is going on house hold bills. But I'm just pleased its finally rego'd.

[Gix11]

Nice one mate. Gotta be happy with that!

[LKC73]

Took it out yesterday arvo for a bit more of a shake down run around there burbs and everything feels as it should. The bike is still a bit smelly and am not sure where this is coming from. It could be the clear residue from the headers or left over grime on the engine but there isn't any leaks, oil window is showing no signs of contamination in the oil which is a big plus.
I'll be taking it easy on the engine due to my own paranoia after such a massive task of rebuilding it.
The tail end will be the next stage of this build, and will update again when this all starts.

[LKC73]

So after that last ride and before the I took it out again I had thought the rear subframe had a big twist in it from last owners crash.
As it turned out, the right pipe was pushing on the number plate holder and was twisting the rear part of the sub frame. I by chance was unbolting the pipes to take some measurements and the tail straightened up! Small win there! I also removed the passenger foot pegs as they wont be used at all.
I took it out Sunday for a small run and then over to the Barry Sheen festival.
Finally the smell is gone, temps got a bit high but that was from traffic heading to the Barry, on open roads it was fine. The other thing I did notice was how light the front end gets loose the steering is like this. so a rethink of the light bracket to place the dampener back on maybe required. Still waiting for my race tail to be made as I cant find a second hand one anywhere. Also now saving up for my new pipes which will be the next part of this project.

[The Phantom]

Teething trouble. Sounds like you are all over it.