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My tear down and rebuild

19K views 90 replies 32 participants last post by  MELK-MAN 
#1 · (Edited)
Hey all, picked up my 2nd R6. It's a 2007 which has been crashed. Picked her up cheap :)

Here is how it is as of now




Aiming to strip down (to check and clean everything) then make it a road legal track bike.

Cheers :)

BIKE NOW FINISHED (more pics on page 9)



vid of rebuild

 
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#36 ·
Man looks like lots of work and progress! Keep it up buddy! :)
 
#38 ·
Termignoni Headers fitted



Radiator fitted back and antifreeze put back in



Time to fit the Bazzaz



I HATE the bodge job connectors it comes with. So I soldered in the power




Def cleaner and more reliable connection



Same for the TPS





All wired up! Finally



DONE!

 
#41 ·
Hey guys! Another update for y'all!

Changed the oil as I had no idea how old it was and the bike came with no history, bike has 10k miles on it, so could well be that old! (didn't look it though)



Out with the old.......



In with the new.........



How she was sitting



Then Termignoni silencer fitted, to match the headers



Hmmmmmmm sexy! loll



That's it for now!
 
#46 · (Edited)
update time!

cleaning up and fitting the throttle back



I routed the throttle cables the wrong way and had to remove the tank, and airbox again so I could route em around the right side of the frame, that ****ing sucked lol



fixed the rectifier bracket



used a metal plate on each side for added strength



fitted the bracket back and all electrics




I wasn't keen on the factory grips, so changed them



I have these grips on all my bikes, really like them :lmao





Front mud guard cleaned up and put back on. Cleaned up great but you cant really tell in this light



Front brake re - fitted. Got some new braided lines and levers to fit still.



Thanks :)
 
#47 ·
Hi guys been busy with the bike

Fitted rear braided brake line and completly flushed and changed the brake fluid. Got the front, still need to fit it thou!



Fitted some gold shorty brake and clutch levers



My fairings turned up

Got a brand new rear tail



Picked up a used set of front fairings for a good price



Rubbing down the bellly pan for a coat of primer



That's it for now. Hopefully will have the belly pan and rear tailed primered this week.
 
#49 ·
Been a while been busy with Xmas and my Bday.

Happy new year all :)

I decided to do some work on the front loom because I thought the layout was messy and because I will be using after market lights i will need different connectors etc I might as well change it!

What I started with



Plan was to move the relays (so I can mount them both in the same place) and move all the light and indicator connectors to the same place

Going in deep!



Moving some things around and shortening / extending wires



Laid out how I want it and giving it a test it still all works lol



Loom taped up again



Wiring up my own connectors



DONE



Relays stuck to intake (As I will be using track fairings there are no mounting points for the relays)

One plug I can quickly / easily connect the lights and right side inidicator
 
#50 ·
Got all the fairings rubbed down, fixed and cleaned ready to be primered

Front / upper fairing

smoothed over the holes for the mirrors as I won#t be using these



holes drilled in front for the front lights



Ready for a coat of primer



Tail rubbed down and ready for primer



Also the lower fairing (had to fix some damage)



Not too bad for first coat of primer









Looking like some weird ass art show



Going to rub them down ever so slightly and then give another coat of primer next up!

Stay tuned
 
#51 ·
Looks great so far! Interested in the outcome! Keep up the good work! I assume you're using some sort of projectors for the headlights? Did you make sure they'd fit in those tight corners before drilling? Just curious... It's a blast working on your bike, right? I'm pretty much done with my build, so I'll enjoy yours and others to keep me sane... :popcorn:

:cheers
 
#54 ·
Thank you man!

Yeah going for projectors, how did you guess? lol and they fit in nice and snug!

I have as much fun working on my bikes as riding them! I'm always on the scope for a new project!

I have seen your build, very nice bike :)

Looks awesome!
Cheers! :D

Very nice, looks like your planning to making usable for street you have your front lights..
Yes, that's the plan! :) Best of both worlds, hopefully!
 
#55 ·
Sorry been a bit slow! It's been so cold here, I have been waiting for it to warm up a bit so I can carry on with painting!

Last few days I managed to get some done!

Heres the lower fairing. Not finished yet.

It's had about 4 coats of paint (with light rub down in between) and 1 coat of lacquer. Will probably go for around 5 coats of lacquer (with a rub down between each coat)



The tail is on its 2nd coat of paint



Upper faring also on 2nd coat of paint



Shot of them all together so you can get an idea of colour scheme!



Peace out!!
 
#56 ·
Finished the fairings. (light was not too good in the pics though!)





There's my blank canvas, need to figure out what to do with it next. Stickers, patterns etc

Also got the MX bike fully prep'd for this season! Can't wait to start riding again!

 
#60 ·
Thanks man, sounds like you love working on your bikes too :)

UPDATE GUYS

Literally been doing 70+ hour weeks at work last month so not had too much time but managed to get an update in

Where the hole was cut out for the front lights it would be leaving a gap around the lights and inner side of the lights due to the curves on the front fairing, so I need to get the filler out to cover up these gaps

Also a shot of one of the lights on the left



Using paper cut out to get a round mould for the filler



View of what i'm working with (Moved to the garage as the workshop is too cluttered with bikes lol)



Ally bracket made up to mount in the lights



Not quite finished yet but roughly how they will fit in



Need to file smooth the filler yet, not finished but so you have an idea!



With the light in. Again please remember these are not finished yet!



BRaided front lines semi fitted haha



Thanks for reading so far!
 
#61 ·
Hey guys update time.

Front fairing and lights are finally finished!

Looks pretty cool I thinlk!



Bracket made up to hold in the lights, this way I can easily adjust height of lights etc



Here is the light pattern from dip





Side view, with indicators fitted



With one of the lights on (How I will mostly be riding it)



Aiming to fit the fairing this week

Thanks
 
#62 ·
That front assembly is look awesome. Keep it up!


Subscribed.
 
#63 ·
Thanks bro!

Another lil update

Fitted side lights have to have these in the UK) think these looks sweeeet!





It's now fully ready and wired up to go on to the bike, at last!
 
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