Jays bike project
 

Its not a zed I know, hell its not even a car but though it might be of intrest to some.

Pick up this reck about a month ago. That has been sat in the garden whilst I got my exams out the way. Its a 1989 VFR400. Bit of a classic, V4 engine with about 59bhp not loads but when you consider this one is around 175kg. Power per tonne is pretty decent :D Was looking at ZXRs (baby ninjas) but the single sided swing arm made me get this one. The Tyga bodykit that transforms it to a modern looking bike was a big brucey bonus :thumbsup:
Seems its been off the road or in a half build form for quite a while. I bought it off a lad who had planned to rebuild it but had failed. So fingers crossed I have better luck with it.

Had a budget which Ive already blow on parts :yawn: Oh well budgets are only there to be broken!

Bodywork obviously needs alot of work, that doesnt phase me in the slightest. The engines are said to be bullet proof but have ordered full gasket set.

Anyway got my last exam tomorrow and so will then be stripping it right back to the frame and start from the base up. Not sure the gf quite knows what she has let herself in for as there are going to be parts everywhere!! :laugh:
Got the ibis white ready to go.

...Updated 19/05................................................ .................................................. ...................................

Made a start on the bike today, got the fiddly bits off. Cant do much more untill I get some more sockets as need a 36mm to for the wheel nut, 41mm for top yoke and a 46mm axle and a locking nut tool for the swingarm. I dont understand why manufactures use such random sizes. :hmm:

Will be updated

+1

^^^^^^^This^^^^^^

wish i had a bike liecence and a bike but no spare funds and dont look like i ever will

be good to see this finish mate will be a good one

Good luck with it pal .... If you get that end result - you will be the envy of the Sunday ride !

Cheers guys gonna be a learning curve thats for sure. Ive told the missus that Im booking the kitchen table for the next month :thumbsup:

These little 400s are great. I had a GSXR400R many years ago and it scared a few bigger capacity bikes in its time. Handled like a dream, turned heads everywhere and was generally a hoot. Hope you get it sorted mate, it'll give you so much fun when it's done.

like it. id go single can, maybe a stubby.

Drew

Yer I agree Drew would prefer to go single can, although it would require replacing the whole system as its currently 2 seperate exhaust each one goes straight through to 2 cylinders each. So gonna spruce up the current one to get it on the road. Then once funds allow go for a single system with a carbon end can something like an Akrapovic system would be nice.

Was browsing youtube the other day and found a video of the exact bike. The exhaust does sound nice, I looked at replacing the cans as one is blowing slightly. Trouble is they were only in production for a very short time and seems they are quite sort after so gonna have to patch this one up for the time being. Had a look at past MOT seems the last 3 have flagged up the exhaust as loud! Have to find a sound tester i think. ;)

Clip: http://www.youtube.com/watch?v=eMPi4J7-JqA

Nice project, funny really as I used to build superbikes but never rode them! They scared the **** out of me!

Best of luck with the exams Jay.

Looks a good project, have to use it as your thesis for your PHD. Then it will be Doctor Jay.

:beer2::beer2:

Cheers Pete, Put it this way together with this and the single seater track car im building with a couple of mates ive learnt more outside of uni than in the classroom. So much for Motorsport engineering!! :shutup2:

Always the way Jay, degree will open doors though.

Thats the plan anyway :)

Jay, long time no see :)
Love the Honda!!! If it looks anything like the one in the last photo it will be fooking smart!

How you doing Dave? Hows that porsche you picked up? Gonna need the 180 MOT'ing when it comes to advertising it. Will have to give you a shout :)

Im good thanks. Porsche is looking alright now. Pulls like a train!! Just waiting till the end of the month to tax it. Got a few mods planned already :)
You getting rid of the 180...?

Fair play Jay. I have been toying with a bike for about 4 years and each spring that comes the more I want. Sadly u think with so many cars about and the speed of a bike it is not worth the risk.

That said I'm to tempted to buy a bike 600cc and then sort the test I look at least monthly Doh

Good luck looks like a classic

Ross

Nice will have to have a nosey round it when your all sorted! As for the 180 I hardly do any miles in it, we take the gfs car on long tips, plus the miles I do cover I'm sat in traffic. I can leave uni same time as a mate on a bike and he's home 20-30mins before me. Plus it makes sense finanacially.

I'd say do it Ross I've been toying with the idea for a year or so. Figured I'd do it now before there's the need to cart kids about. Winter will be tough but that's what waterproofs are for. :)

Only thing with a 600cc is that I'd be put off by the power of it being a new rider, I'm doing my A2 test so the bike will be restricted to being with. Once I get to grips with hanging off it. You can do a top up course to allow it to be derestricted. Wouldn't trust myself with full power straight away. Also the DAS direct access learning test is expensive!!

naaah, bikes are so much faster, its worth the risk.

i did afull test when i was 21, bought a new R6 for my first bike. was good but i wasnt used to revving that high! got knocked off in traffic as someone didnt see me :slap:

got an R1 after that, amaaaaaazing.

Drew

Good luck with the project, i am thinking of getting my bike license now i am moving to a place where i could store it safely....

however for me i want a bike i can sit on not perch on.... i am a bit too tall for most sportbikes...

will looke gorgeous when you are done, if it looks like the pic you posted!

Tiny update today. :)

Well did my CBT a few days ago, was great fun even if it poured when out on the road. Guess it's all part of it. Did it on a little CG was a right laugh, great little bike.

It's slightly scary they let youngsters out on the road after a days training, with very basic road knowledge!!

As far as the build goes I've rebuild the carbs yesterday, some of the jets were in the wrong carbs which wouldn't have helped it's running!!

Currently stripping down and refurbing the calipers.

Got a wait for the locking socket to remove the engine mount bolts apparently honda are behind on supplies due to the tsunami (spelling fail?). So got a few weeks before I can drop the engine to check shims

Got our house contract through for renewal and one point is that there's to be no repairs of motorcycles, cars or commercial vehicles unless occasional maintenance and registered to the tenant. Guess a full strip down and rebuild in pushing the boundaries slightly! :laugh:

possibly just a touch! then again it is occasional :laugh:

i think it is fine - it is bascailly to stop you doing it and breaking cars etc.. or running business out of it etc etc..

Yer thats what I took it to mean, better clean the oil off the paving before anyone moans though! Its out the way so cant see any issues. As long as we dont have a flat inspection whilst the engine is in the flat!! :laugh:

Grand son just passed his motor bike test, got a Pug V-Clic, time flies, remember saying I'd do the MGB up for him.

As you say Jay, let him out on the road after a test, took him straight out on to the dual carriageway at Tower Park. He was the lead rider, must be a bit scary.

Last time I saw the MGB it was hoisted up on top of a container at the local scrappy.

Owner thought it was too good to break up.

:clap::clap::clap:

Yer I was alright as only had to concentrate on the controls of the bike as used to being on the road. Must have been on the bike 3hrs before on the road. For someone that has got no road experience it must be a hell of alot to take in. Prob why kids on scooters are so clueless.

Big jump from a bike to a scooter, as long as they don't fall off, can stop and start, they are let loose on the road.

Glad we don't have to stay up waiting for the putt, putt coming home.

:clap::clap::clap:

Attacked the exhaust today, I was going to fill the dents and spray it gloss black although decided to rebaffle it and thought if I was opening it up may as well replace the tubes with new carbon ones.

I could hear something rattling around when the cans were shaken?! So drilled out the rivets and opened them up. Only for the baffles to fall out. Both were broken and were in two. Would be fine if they were removable although they seem to be welded in on the inlet side. In a moment of fury I took a hammer and screwdriver to one but just bend what was left of the baffle.

Any tips on what I could do?! Thought about getting a bit of pipe welded on the end of the inlet so I can screw a removable baffle on.

The baffle is 41mm diameter by about 270mm long. Thats a rough length as not sure how far down the tube it goes.

http://www.mijexhaustparts.com/index...emart&Itemid=2

something like that. ive not looked on the net too much.

Drew

Cheers Drew just found them through ebay as well :) Although its a quid cheaper direct, it all helps! lol

The Carbon tubes are coming from PJ Engineering for an ?80 total cost they will look like two new cans!

Bit of an update, been really busy with work and still waiting for sockets to drop the engine!!

Although recieved a few bits to tidy up the exhausts. One slight issue is gonna need the end caps replacing as they dont fit too well now.
Baffle and packing:
Carbon tubes, these are gorgeous photos dont do them justice!
Front calipers painted.
Bought a blow torch yesterday as couldnt find my old one for the life of me. So have now seperated the rear caliper as it was seized tight.

Hope to remove the engine this week and do all the gaskets, lap the valves and check the shims. New clutch and then refit next week.

Passed my Mod 1 last week have Mod 2 booked for end of July so would like to have the bike ready to go soon after that.

glad to see you got the rear caliper apart... looks rooted can you save it?
Have you done a bike mechanics course or are you self teaching?

The caliper will clean up alright bit of elbow grease and paint and it will be fine.

As for a course its much like the car, got a haynes and a member of 400greybikes which is a helpful forum. Other than that just a bit of common sense, its pretty straight forward. If you can work on a car then a bike shouldnt be any harder.

Plus Ive got a mate who knows the VFRs CRB 400s almost inside out back to front so he can always lend a hand if im completely lost. .....Ive gone and jinxed myself now!! :slap:

Only just seen this thread! Good luck with your Mod 2 Jay!
That fairing makes it look like a new bike!
I know what you mean about going out on the road after just a few hours. The scariest part for me was passing my Mod 2 after just 2 lessons, so basically, 10 hours on the road. Then jumping on my 650, which revs to 12k! Mental.
You will enjoy it though, just clocked up 5000 miles in under a year :-D

Nice one and congrats on the mod 1 and good luck with the mod 2... got to sort mine out over the coming weeks, not sure if I should das it or do them as and when I can because das is about ?750, might be less with my own bike but not sure if they would let me do that on the rf600.

Will all depend on how many days you need, believe the Mod 1 is ?18 and Mod 2 about ?80 do it with a training school and will be alot more. If I pass first time will have cost me just over ?500. Although I am doing the A2.
CBT ?130
Mornings training and afternoon Mod 1 ?130
Days training and following morning Mod 2 ?255

thats not bad... I have ford air field to practice on so hopefully it shouldn't be to bad.
how daft is this.. a years insurance for the rf with no ncd and its my first bike is ?230..