VFR complete rebuild

Discussion in '5th Generation 1998-2001' started by OnlyVfr, May 16, 2021.

  1. OnlyVfr

    OnlyVfr New Member

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    Handles sprayed.
     

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  2. OnlyVfr

    OnlyVfr New Member

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    28. Wheels powder coated... few bolts broke and had to drill, one was done with helicoil...
     

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  3. OnlyVfr

    OnlyVfr New Member

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    29. Valve check, new clutch plates, springs, covers powder coated, all seals and gaskets changed, engine bay cleaned, lots of jobs done. Few studs broke off when taking exhaust down, so..welding, drilling etc was used to extract broken off studs... Crash bar corroded and welded together to engine and that was a pain as well...
     

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  4. OnlyVfr

    OnlyVfr New Member

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    Only few exhaust valves were in spec, other were near at the limit or too tight. Mileage 41k miles.
     

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  5. OnlyVfr

    OnlyVfr New Member

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    Parts were sprayed with heat resistant paint, then lacquered. I am considering to make a clutch window... Don't know yet, have to think about it.
     

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  6. OnlyVfr

    OnlyVfr New Member

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    I found it easier to assemble main and rear frame , then do wiring and then lower it onto the engine.
     

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  7. OnlyVfr

    OnlyVfr New Member

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    Broken studs were cnts.. Still had some thread after studs broke off so I put a nut on it and weld it. The studs were snapping just behind the nut all the time. So I put a nut on, and used 5mm drill bit to make first grove, use it as guide, then cobalt left drill bits 3, 4, 4.5 mm but studs would not move... Eventually used extractors to get few out, and cobalt left drill bits took 1 out... I tried everything, heating the stud, freezing the case etc, but old good drilling did the job..
     

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  8. OnlyVfr

    OnlyVfr New Member

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    Cleaning the engine bay was some task... bike was not touched in 21 years or so... Valves were never done either. I eventually got hard nylon brushes for the drill, lots of industrial grade tfr, because brake cleaner was too weak for anything... wanted to sand blast the entire engine and spray, but I manged to clean as much as I could.
     

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  9. OnlyVfr

    OnlyVfr New Member

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    30. I always wanted better front brakes and after delinking them, having braided hoses etc I got free CBR 919 calipers. So decided to rebuild them, new seals etc.
     

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  10. OnlyVfr

    OnlyVfr New Member

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    I used old clutch line and bicycle pump to push out old pistons.
     

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  11. OnlyVfr

    OnlyVfr New Member

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    31. Now, after rebuilding CBR calipers, rebuilding forks, having braided hoses I had to make brackets for those calipers... Problem was that left and right forks have different mounting points, and left fork has different vertical off set between top and bottom mounting points... That was some task to measure everything to 0.25 mm using basic stuff... Started from just cardboard cut offs, then plastic, then steel plates and so on... Brake pads had to be placed exactly in the right spot on brake discs, left and right off sets, up and down, then in and out positions... Once that was done calipers were installed on top of brake pads with some spacers between pads, so spacing is perfect... Once all calculations were done a friend of mine transferred it into Solid Works, he did all the job designing and implementing my measurements. We had plenty of plastic prototypes printed, took few weeks before we got the final product in plastic with precise measurements etc. Once we were happy with plastic printed prototypes I got 6082T6 block of aluminum and milled it using professional workshop who done job for me. After milling spraying was done with special paint for aluminum , then lacquered. Everything fits perfectly. Just remember , you need to change your MC to 5/8 . The 1/2 won't push enough fluid and you will never have any brakes or stopping power. I got mine from CBR600 and rebuilt it from 0 too.
     

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  12. OnlyVfr

    OnlyVfr New Member

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    I am sharing all prototypes made, want people to see the process and how it works. It is a good experience to have. I did not want to make a straight lines caliper bracket like on every other bikes , instead I wanted bracket to follow shape of the caliper itself and look nicer also stronger.
     

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  13. OnlyVfr

    OnlyVfr New Member

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    "Paint" peeling of the calipers is not really paint, it is plastic dip spray. I sprayed many parts to protect them from damage while working on them, then I used normal spray. You can peel off plastic dip no problem.
     

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  14. OnlyVfr

    OnlyVfr New Member

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    You need quite a big washer for the left fork where the lower brake bracket mount is. You have a metal tubing inside that mount and it needs a big washer on top of it so the bracket does not move. I used my old bar end and cut a nice washer for it with 8mm hole. Remember to use high tensile bolts when assembling brakes. The brake lever is also different than old one which had a push rod vs CBR600 5/8 has a flat surface.
     

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  15. OnlyVfr

    OnlyVfr New Member

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    Special thanks to Eoghan ( Solid Works and other design jobs, including mechanical jobs ) and Peter ( for assisting me with most difficult problems, from programing, electrics, electronics, calculations, materials and many many more), Pat ( knows lots about bikes ). If anyone is interested in these brackets let me know, they are not cheap to make tho.

    I know, some will say it would be easier to get VTR lowers, shave off 2mm of lower calipers mounts and swap with existing lowers then get new fender or modify existing one. However, I rebuilt forks months before this project and did not want to do it. I now have new VTR lowers but I will keep them, you never know. Also, I love challenges and learning new stuff. It was great learning curve for me.

    PS. Just remember, when you have bar raisers like I do, the CBR900 MC and reservoir will be too high and will hit your fairings, you won't be able to turn, so get CBR600 one with the same looks and height like in VFR.
     

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    Last edited: May 20, 2021
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  16. OnlyVfr

    OnlyVfr New Member

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    Right, this is all. I did not upload all pictures, no point and it is also painful not to be able to upload more than 1 picture at once here :(. Had to resize them etc and then upload one by one. I am not currently riding this bike, no time or weather for it. Once clean it up, do some detailing job on it I will post final pictures here in this post. It might take few weeks before I get to ride it. Project took long time, just over 6 months, every Saturday, sometimes I managed to get Friday in. Most annoying things were incorrect parts arriving or not arriving at all... Waiting for other people, equipment breaking, tools breaking down and so on. Typical things, nothing to bitch about too much. Don't ask me how much I have spent, I am afraid to add it up XD. If anyone need any help, more pictures, explanations, advice while doing their own bike I will be more than happy to help you:) Of course if I can help you:) You can post away, thank you for patience.
     
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  17. SilverBulletCSVT

    SilverBulletCSVT New Member

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    Not even a single photo of your completed bike? I jumped to the end of thread expecting to see one.

    For your photo attachment issues try Tapatalk. One click posting from your phone, multiple photos at same time, no resizing, etc.
     
  18. OnlyVfr

    OnlyVfr New Member

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    Hi,
    Bike is very dirty, did not have time to wash it. Would not show work and effort put into this bike when dirty. I will try to wash it over the weekend, then take proper pictures and upload here:) Thank you for advice on the app, but I don't use smartphones, just old good 6310i :D
     
  19. pi-on

    pi-on New Member

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    Very nice work. Appreciate the time spent in documenting the steps you took in your build.
     
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  20. OOTV

    OOTV Insider

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    Just went through the thread, mostly looking at the pics but have to say, looking like quite the project. I'm sure once you're done you'll be proud of your accomplishments. Nice work so far.
     
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