VFR 800, my first build

[I0seb]

G'day Gents, how are we?

On Chris' advice I'm posting my build up here along with over at customfighters. It's been a long journey but one that's finally reaching a rideable/registerable conclusion. Hope you enjoy!

At the start

https://i.imgur.com/Dd0ydR1.jpg?1

Stripped

https://i.imgur.com/5q1Q9tO.jpg

Frame and subframe hydroblast and welding

https://i.imgur.com/2qrqF3v.jpg?1

https://i.imgur.com/jc0blum.jpg?1

New tail

https://i.imgur.com/j8ewwp9.jpg

With undertail exhaust

https://i.imgur.com/4x7KqWz.png

Moving states

https://i.imgur.com/wYdyc6k.png?1

New home

https://i.imgur.com/sDRCF9g.jpg?1

New dash

https://i.imgur.com/TvX1Tn4.png

New bars

https://i.imgur.com/WS3qalD.png

https://i.imgur.com/Rf7LsVM.png

And that brings us up to speed. Working on the radiator mounts at the moment, also need some new front brake lines and some rearset adaptors.

And paint obviously :P

[rod185651]

Welcome Mate, there are a few cool VFR builds going on. Looking forward to following your progress

[hooligan]

Glad you joined in, Luca.

[ozzy1100]

Welcome and ace work

[LKC73]

Welcome, bike looks like its coming along nice.

[Gix11]

The CBR tail works well on it hey?
Welcome aboard mate, thanks for coming over.

[I0seb]

Thanks to a couple of irrigation fittings from Bunnings, the cooling system is up and running. I've also figured out how I'm going to mount the radiator.


Initially I planned on doing something similar to what SEBSPEED over on CF did in the hope there would be space to mount a fan. Didn't look like there would be though so instead it is sitting slightly higher and further back which gives me a lot more clearance to the fender.


https://i.imgur.com/3kf0Toi.png


https://i.imgur.com/hzDjNke.png


Added a lower rail to the left mount to secure the overflow tank to, I've always liked the look of the fake NOS bottles...


I also refit my Rapid Bike Racing module, some issue with the map is causing the bike to die at 3000 RPM when it is active though, maybe someone here can share some wisdom on that. Currently just running a map that came with the module for a slightly modded bike, that's probably where my issue lies lol.


https://i.imgur.com/0ZJ9feV.png


https://i.imgur.com/ceMv8XN.png


https://i.imgur.com/Hl1lawv.png

[hooligan]

the rapid bike racing will self tune using the factory narrow band O2 sensors.

I have a RB evo on the way from quicklap performance and had to buy a stock exhaust to get a set of O2 sensors that i ditched years ago.

[I0seb]

the rapid bike racing will self tune using the factory narrow band O2 sensors.

I have a RB evo on the way from quicklap performance and had to buy a stock exhaust to get a set of O2 sensors that i ditched years ago.

Not on the 98/00 model, no O2 bungs. Gonna get it dyno tuned eventually, just need to get rolling first.

[geesexar]

welcome aboard good lookin vfr

[hooligan]

Not on the 98/00 model, no O2 bungs. Gonna get it dyno tuned eventually, just need to get rolling first.

98/99 no 02, 2000/2001 has sensors.

Go over to vfrd (vfr discussuion) and search for rapid bike threads. They are the ones who got enough interest going to get rapidbike to make the harness for vfr's.

[I0seb]

98/99 no 02, 2000/2001 has sensors.

Go over to vfrd (vfr discussuion) and search for rapid bike threads. They are the ones who got enough interest going to get rapidbike to make the harness for vfr's.

Yeah that's why I initially got interested in them, awesome product so far and the support from the aussie headquarters has been great.

[I0seb]

Carted the bike over to a mates place to angle grind up a couple of brackets, nice to see her in the sun again.

https://i.imgur.com/FztODMA.png

https://i.imgur.com/LeXA1Fi.png

https://i.imgur.com/2dPh65x.png

Brackets aren't pretty but they're solid as fuck, radiator defs ain't going anywhere and I have plenty of clearance to the front fender.

New brake and clutch lines and temp sensor are coming this week, once those are on all that's left is the rearset adaptors before I can get her registered, tuned and start work on the painting and a couple of filler panels.

[Gix11]

Another great build thread. Thanks mate.

[ozzy1100]

Much coolness

[Fish]

Looking sharp there chief.

[I0seb]

New brake and clutch lines are on, temp sensor is wired up and she's good to go, or at least good enough to do sick burnouts :D

https://i.imgur.com/zvtWQ2y.png

https://i.imgur.com/tXMidZY.png

[ozzy1100]

looks ace man, was just looking at how horn your frame looks wet blasted, fucking amazing isn't it.
I am of coarse biased as o own a hydroblaster but as yet I haven't done a ally frame because all my stuff
is steel framed.
looks a hoot to ride

[LKC73]

Done well mate, like Ozzy said, looks like a blast to ride!

[I0seb]

looks ace man, was just looking at how horn your frame looks wet blasted, fucking amazing isn't it.
I am of coarse biased as o own a hydroblaster but as yet I haven't done a ally frame because all my stuff
is steel framed.
looks a hoot to ride

Honestly I think the hydroblasting is my favourite part of this build so far, I'm beyond stoked with the results and Greg at Woody's Hydroblast was an absolute pleasure to work with.

[ozzy1100]

Honestly I think the hydroblasting is my favourite part of this build so far, I'm beyond stoked with the results and Greg at Woody's Hydroblast was an absolute pleasure to work with.

I have had my own machine for about 2-3 years and even
still I giggle like a loon ever time I take things out the cabinet lol

[hooligan]

Looks great, Luca.

[I0seb]

Did some more work on the Suzuki while the VFR is waiting for parts, been having fuel starvation issues on a race launch which I think might be related to the dodgy fuel tap setup I'm currently running. Also fitted a custom seat cowl :D just needs paint.

https://i.imgur.com/hyIRTXx.png

[ozzy1100]

Very nice

[Gix11]

Time has made these a very cool looking bike. They were absolutely everywhere in their day and now seeing one in stock condition is a rare sight.

[ozzy1100]

Time has made these a very cool looking bike. They were absolutely everywhere in their day and now seeing one in stock condition is a rare sight.

And the prices are starting to represent so, slab sides omg

[I0seb]

And the prices are starting to represent so, slab sides omg

Especially so with parts! Literally cant find a working stock fuel tap anywhere in the world, probably going to have to bodge fix my old one.

[ozzy1100]

Especially so with parts! Literally cant find a working stock fuel tap anywhere in the world, probably going to have to bodge fix my old one.

Have a look at other bikes the hole spacing and shape is common from memory but not many are twin outlet
check pringal as well for aftermarket

[I0seb]

Have a look at other bikes the hole spacing and shape is common from memory but not many are twin outlet
check pringal as well for aftermarket

Assuming you meant pingel? Haha

They are pretty much the only option now, I've looked at other models and all are single outlet sadly. It appears I've fixed the issue by drastically shortening the fuel hose though.

[JimZXR]

Have to admit that I’m not big into Suzuki’s but that Gixxer looks awesome fully faired!

[ozzy1100]

Assuming you meant pingel? Haha

They are pretty much the only option now, I've looked at other models and all are single outlet sadly. It appears I've fixed the issue by drastically shortening the fuel hose though.

Yes pingel, stupid auto correct lol

[I0seb]

CRF 450 rear master cylinder arrived in the mail today, finally have working rear brakes. Still need to bleed them, probably my least favourite job behind wiring :shootme:


https://i.imgur.com/8swi58C.png


https://i.imgur.com/kmVDlL1.png


Going to tidy up the wiring behind the radiator a bit then it's off to the dyno.

[ozzy1100]

That's a neat little master

[I0seb]

That's a neat little master

Yeah it's super compact, integrated res and all. Didn't have enough clearance to the new undertail exhaust with the old mc.

[ozzy1100]

Yeah it's super compact, integrated res and all. Didn't have enough clearance to the new undertail exhaust with the old mc.

Cheaper than a brembo that's for sure

[Gix11]

Yea, what Lynton said. Good choice.

[GammaBoy]

You can see why Ducati and MV hung the master horizontally off the cases - much easier to make it tidy.

[I0seb]

Spent a very frustrating hour cutting down the muffler, got there in the end although it's a little dodgy and needs some cleaning up with an angle grinder.

https://i.imgur.com/TcUwKDC.png

https://i.imgur.com/C7PcFdU.png

Sounds and looks heaps better, has a much deeper and throatier note. Vid here (https://streamable.com/3f9p0), probably doesn't come across to well on the phone cam though.

Sadly after bleeding the rear brake, the 450 mc just didn't have enough power to activate the big 2 piston VFR caliper. Not surprising when you compare the pistons. Considered boring it out but there just wasn't enough meat.

https://i.imgur.com/tXOsDdt.png

Luckily, late at night and while quite drunk, I had a brainwave and cracked out the drill and hacksaw and came up with this (sorry for the crap photo).

https://i.imgur.com/CrvcOcJ.png

Stock mc mounted in reverse with a new hole drilled for the bottom mount. HRC style res made out of a piece of OEM brake line and sealed with an OEM nut and bolt from... somewhere. Shockingly, it works great!

Booked in for the dyno on Tuesday, fingers crossed all goes well!

[Gix11]

That pipe does sound good in the video. I'm liking the overall look of it. Nice work mate.

[LKC73]

That pipe looks way better shorter now, sound beef as well. Nice job!

[I0seb]

Thanks fellas!

Sadly all did not go well with the dyno, we discovered a MASSIVE leak from between the V once the bike reached high temperature from what I can only assume is the thermostat.

Normally it's just a matter of removing the airbox and fuel rails to access the V, sadly someone, probably me, put the intake boot clamps on the wrong way when I dropped the engine last time, meaning they cant be accessed from the gap in the frame they usually are, meaning I'm going to have to drop the whole engine out to access them...

https://i.imgur.com/HHaAYXN.gif

[hooligan]

now that is a motherfucker.

[LKC73]

Oh shit, that's a huge pain in the arss. Poor bugger.

[Gix11]

My "That-sucks" meter just started giving a reading.....

[I0seb]

After many long hours of labour and much swearing, I managed to lever the throttle bodies off without removing the engine!


https://i.imgur.com/jXlyfSv.png


And I think we've found the culprit...


https://i.imgur.com/otZf1GL.png


Pulled out the thermostat and little hose nipple thingies, sure enough o-rings were completely stuffed, they also smelt like shit which can't be a good sign.


https://i.imgur.com/K9mqUWd.png


Replacements ordered, in the meantime I have some plans with fans, specifically 3 80mm PC cooling fans which will fit in nicely behind the radiator.


Only thing I'm struggling with is how to wire them so they activate at a certain temperature now that the stock temp sensor is no longer connected. Any ideas?

[hooligan]

the fans circuit comes on by completing the earth. Temp sensor isn't needed.
From memory, fan circuit is always getting power.
the rad has a fan switch (brass threaded sensor, single spade connector) that threads into it. When that gets hot enough, it completes the earth circuit, fan comes on.
I've earthed my rad to the frame.

you can either put the fan switch back in the rad, or just wire in a manual override, or both.

I've got 3x 80mm fans from jaycar on my rad.

[I0seb]

the fans circuit comes on by completing the earth. Temp sensor isn't needed.
From memory, fan circuit is always getting power.
the rad has a fan switch (brass threaded sensor, single spade connector) that threads into it. When that gets hot enough, it completes the earth circuit, fan comes on.
I've earthed my rad to the frame.

you can either put the fan switch back in the rad, or just wire in a manual override, or both.

I've got 2 80mm fans from jaycar on my rad.

Ok cool, I'm running the VFR750 rad which has a single pin temp sensor on the left side, assuming that's the same thing.

How's the cooling? I reckon I can fit in two 120mm 150cfm fans which should be enough to keep the bike from overheating when stopped.

[hooligan]

I commuted on it, so good enough for me - I only want to use it for open road/track day shenanigans, so if it commutes at 100, open road i'm sweet.
And yes, same thing.
I could only fit 80's in because my custom rad is small.

[I0seb]

Quick update, no photos as it's mostly under the hood. Got the new o-rings, cleaned up and refitted the thermostat aaaaannndd...

NO LEAKS!

https://i.imgur.com/TuYQdcY.gif

Also finally properly mounted the speedo pickup, gonna pick up some chicken wire tomorrow to pack the muffler for inspection, fingers crossed I pass :D

[LKC73]

Hahaha I read that gif in Borats voice.....

Good luck with inspection mate, hope it all goes well.

[Fish]

Good on ya mate, fingers crossed you don't get any more little gremlins, mechanical or inspector...

[I0seb]

I swear to God I'm cursed, was giving the bike a once over before the inspection in the morning. As I was checking the front wheel, the front sand slipped and the bike fell on me, breaking the right mirror mounting thread inside the bars and, more importantly, ripping my favorite pants


https://i.imgur.com/OqkPALa.gif


So yeah, gonna need new bars and mirrors, hopefully I can get them locally

[hooligan]

numbers (Wollongong) is selling a set of MT09 fatbars. When mine tipped over it punched a couple of holes in the petrol tank.

Find your own pants.

[rod185651]

numbers (Wollongong) is selling a set of MT09 fatbars. When mine tipped over it punched a couple of holes in the petrol tank.

Find your own pants.

Thanks Chris, I have MT09 bars and a set of Renthals Fat bars also

[I0seb]

Crisis averted!


https://i.imgur.com/q5qhpc2.png


I managed to cut a new thread into the bar insert using a tap and fitted a slightly bigger bolt, works great but I will end up replacing the bars anyway, got my eye on a set of renthal fat drag bars.


Also had a fiddle with the map, ended up putting it back to stock and it appears to be running much better now, suppose the extra length of my undertail and the chicken wire baffling are restricting the flow a bit.

[hooligan]

And rear set adapters!!!

[I0seb]

And rear set adapters!!!

Seb reckons they'll ship in a couple of weeks, cant wait to ditch the shitty stock ones!

[I0seb]

Just got back from a brief holiday, fitted a CBR1000rr rear master which seems to match up to the 2 pot VFR rear caliper nicely, lever feels good and solid. Also came with a proper HRC reservoir which was a bonus.


https://i.imgur.com/nhAyhik.png


Roadworthy inspection tomorrow, for real this time, not gonna run away for a week :P

[I0seb]

Sadly didn't pass inspection, apparently my headlight and mirrors weren't ok, need to be OEM not just ADR. Bike performed well on the ride there though, cooling system worked well even on a 37 degree day. However I noticed a fair bit of chatter from the front brakes under even mild breaking, presumably the calipers are in need of a rebuild or the steering head bearings are fucked.

[LKC73]

Thats bullshit Seb, ADR gear is compliant, that should be well enough! Sorry to hear it didn't go to plan.
Whats the next plan for it then?

[rod185651]

Sadly didn't pass inspection, apparently my headlight and mirrors weren't ok, need to be OEM not just ADR. Bike performed well on the ride there though, cooling system worked well even on a 37 degree day. However I noticed a fair bit of chatter from the front brakes under even mild breaking, presumably the calipers are in need of a rebuild or the steering head bearings are fucked.

Also could be warped discs

[I0seb]

Thats bullshit Seb, ADR gear is compliant, that should be well enough! Sorry to hear it didn't go to plan.
Whats the next plan for it then?

Already ordered a Honda Hornet headlight, not sure what mirrors I'll go with yet, they'll be removed immediately anyway. Also got a set of stainless headers on the way with 02 bungs so that'll save paying for a tune.

Hopefully I'll get the rearset adapters late December at which point I'll also reroute the rear brakeline through the swing arm so I can ditch the chainguard after inspection.

Finally I'm considering hacking up a CBR 600rr race bellypan to fit the VFR, sort of emulating the Ducati look with the headers sticking through the fairing.

https://i.imgur.com/WERWpsR.png?1


Also could be warped discs

I noticed a fair bit of brake drag when I was spinning the wheel up on the front stand, definitely something I'm going to have to look into.

[hooligan]

I think I have a set of stock rotors if you need them.

[Gix11]

That OEM thing is bullshit mate. As long as they are ADR approved then they are fine. If your mirrors are way too small that may have just been a trigger for them. Take it somewhere where they know what they are doing next time.

[I0seb]

Just got back from level 2 of the California Superbike School at Philip Island, awesome track and I've defs been bitten by the bug. Next bike in my garage will have race fairings :D


https://i.imgur.com/7HIy9zh.png


Came back to find my new headlight waiting for me


https://i.imgur.com/mJp5pWu.png


Off a Hornet 900, may also use a front fender off one as the CBR one looks a bit fat to my eyes.


I've also got a set of stainless headers and a new muffler on the way. last thing to deal with will be the mirrors before I go for another inspection., likely not going to be able to get any work done until late January though :(

[Gix11]

So you got to ride S1000RRs around Phillip Island??

[I0seb]

So you got to ride S1000RRs around Phillip Island??

Yup, was awesome

[I0seb]

Hey all, long time no post.


I had planned on updating today with photos as I've got on a new headlight, mirrors, seb's rearset adaptors and I hoped I would have a new black widow stainless system on. Given what happened last night can't say I'm a huge fan of their product.


First off the exhaust was clearly not the same shape as the OEM headers, something that became doubly clear when I tried to fit it. Took 2 of us 2 hours to get the joints together but when we tightened down the flanges to seal against the gaskets, one of the flange bolts sheared off.


So... Yeah


Now I have to find time to drop the engine out, not sure I can even be bothered at this point.


EDIT:

Pulled my finger helped and with some help from the missus dropped the engine, quite a challenge with no jack or milk crate. Also gives you a look of the new headlight and mirrors.

https://i.imgur.com/RZD2BOf.png

[LKC73]

Sucks dude about the black widow pipe! I only have slip on's as they don't make a full system for the R1.
Man she is in bits now, hope you can get it all sorted out.

[Gix11]

Always admire you guys that do this in basement parking bays. Full effort.

[I0seb]

I miss my garage so much haha

New exhaust studs are on order, ETA 22nd Feb, need to come from Honda Japan. In the meantime I'll be working on my R3 track bike, might out some updates of that on here if you guys are interested.

[Gix11]

Why not? Any project is interesting.

[LKC73]

Why not? Any project is interesting.

Absolutely agree, post it up, its a bike, its getting modified.

[Fish]

What they said ^^^^

[Fish]

Also, more pics...

[I0seb]

WE A UNICYCLE THREAD NOW BOYS


https://i.imgur.com/aT5cn20.png


Nah but for real, broken stud is out, helicoil is in


https://i.imgur.com/RmbarYb.png


Managed to wiggle the engine into the frame with no jack, solo. I bolted on the two rear mounts first, deadlifted the engine up and very gracefully slammed the front mounting bolt through with my foot :D


Anyway gonna drill a hole to route my rear brake line through the swingarm later this week, then I'll put her back together properly. Still waiting on my R3 race shock and ECU, will chuck pics of that and smog block off when they arrive.


EDIT: Also got a new phone so the pictures should be heaps better.

[Gix11]

Mate, you have a rock and roll method of sorting shit. I like it.

[I0seb]

Mate, you have a rock and roll method of sorting shit. I like it.

Haha thanks, the way I figure if it's stupid and it works, it's not stupid.

[I0seb]

https://i.imgur.com/hxPIXdR.png


https://i.imgur.com/krGkYDR.png


https://i.imgur.com/P244p8F.png


Old girls got her legs back

Also really happy with how the two PC fans fit, need to find time to wire them up and make some mounts


https://i.imgur.com/vSynr0M.png

[I0seb]

Ran a piece of rope to pull the new brake line through


https://i.imgur.com/jOxV7kb.jpg


https://i.imgur.com/kdD3uPw.jpg

[LKC73]

Is that how they run the brake line normally? if not, that's a very cool mod idea.

[I0seb]

Is that how they run the brake line normally? if not, that's a very cool mod idea.

Nope, not standard. The holes are originally there for drainage, just need to widen the one near the caliper to 18mm to fit the banjo fitting through.

[I0seb]

New brake line arrived and installed


https://i.imgur.com/afTNgvk.png


https://i.imgur.com/P4w13OF.png


https://i.imgur.com/Bq5FuoC.png

[geesexar]

did a similar mod with the brakeline with the sssw on my 7/11...looking good

[Gix11]

That's coming together well mate. Just an observation. Have you had anyone sit or push down hard on your tail unit since you added that brake hose? Just curious as to whether the compression will make the line longer and stick into the coil spring. Long shot, but a lot of people have done mods over the years and not allowed for suspension movement when it's just sat on the shed - they find out on the first ride - some with nasty results.

[I0seb]

Sorry about the lack of updates fellas, totally forgot to update over here.

I have since moved the brake line slightly so there should be no issues with it catching. I also had the pipes ceramic coated and have begun working on mounts for my PC fans, will grab some pics when I'm home.

Also chassing some sort of exhaust that will.get me through inspection but fits on my mid pipe, would love some suggestions haha, all I've found so far is supertramp.

[I0seb]

Aaaand here's the pic

https://i.imgur.com/DM1mUDd.jpg

Guys at Capital Precision Coating did a great job

[Gix11]

Shit yea! That looks great hey? Nice work mate.

[I0seb]

Shit yea! That looks great hey? Nice work mate.
Thanks man! Glad I went with titanium, the colour is even better in person.

[I0seb]

Can't resist taking a pic of that silhouette

https://i.imgur.com/XcfzgML.jpg

What colour should I paint her?

[LKC73]

Its looking great, and maybe have white wheels red tank and tail with fender. seams to work so far bar the front wheel.

[Bob]

^^ what he said. I think a res and white combo would work a treat.

[I0seb]

Definitely what I'm leaning towards at the moment, I think once I get the front wheel painted white it will contrast with the front fender much better.

[Gix11]

Yep, will polish up nicely with a new paint job.

[I0seb]

Took her for a slightly illegal ride, brakes feel good, suspension is good, power is great as is the sound. Reckon I'm about ready for another inspection, just need a baffle ;)

https://i.imgur.com/blc9Qzp.jpg

[LKC73]

Bike looks great and I'm sure you are pleased as mate! Great job.

[Gix11]

Good times! Nice one mate.

[ozzy1100]

Outstanding

[Bob]

Great feeling to getbyour project on the road. Well done mate

[rod185651]

Fuck yeah! We all know that feeling