HONDA CBR400RR rebuild

[COP_B8]

Just thought id start an ongoing thread as to my project to completely strip, rebuild and hopefully make better my motorbike, a 1991 Honda CBR400RR.

No i didnt crash it to prompt this, however did lose my license, and in order to remove the temptation to ride it whilst disqualified I decided to 'disable' it by removing the front wheel :yes: however in doing so I found myself removing most other parts and am in the process of fixing a few little problems it had, replacing some parts, and planning new colour schemes etc :yes:

Below are a few pics:

Picture 1: Stripping the Frame
Picture 2: How the engine used to look

[cowpoos]

burn it.....it will improve your honda no end....and use the insurance money to buy a suzuki!!!

[COP_B8]

Things done so far:

- Completely stripped the rear subframe and powdercoated gloss black

- Stripped and Rebuilt engine, painted matt black, awaiting New Clutch.

Does anyone know where I can buy the tool to remove the bolt attaching the rear swingarm to the frame, it looks to be like a notched socket.

Planned things to do:

- All new Fairings, single seat rear
- Re polish Frame, Swingarm, forks
- Get Polished the Wheels, Side engine covers, and all the bits hanging off
the bike (pegs etc, exhaust hanger, triple clamp.....)
- Rebuilt Suspension
- Full repaint

[COP_B8]

burn it.....it will improve your honda no end....and use the insurance money to buy a suzuki!!!

You really think as an unlicensed rider I qualify for insurance.....

[cowpoos]

You really think as an unlicensed rider I qualify for insurance.....
burn it anyway......and get a licence

[limbimtimwim]

Does anyone know where I can buy the tool to remove the bolt attaching the rear swingarm to the frame, it looks to be like a notched socket.That bastard is called a 'Castellated' socket. Get out the yellow pages and ring around the tool stores.

[COP_B8]

Cheers! tryed Mitre10, Repco, Supercheap.....they all had no idea..... so will call a few this arvo.

[bugjuice]

buy a 26mm socket (or whatever the overall nut size would be, if it were a normal nut), then get happy with the angle grinder, taking off 4 large chunks to leave 4 'prongs'. Works fine. Postie and I have done the same for various bits. Don't bother paying for expensive stuff like that, when you're only going to use it a couple of times

[Postie]

good luck with the rebuild mate, if you have any questions or need some advise or ideas, gimmie a PM and I'll see if I can help. I rebuilt mine a couple of times. Once when I got it, then once when I crashed it. Good solid bikes those are

[cowpoos]

good luck with the rebuild mate, if you have any questions or need some advise or ideas, gimmie a PM and I'll see if I can help. I rebuilt mine a couple of times. Once when I got it, then once when I crashed it. Good solid bikes those are
the only advice he needs is how not to burn his fingers with the matches!!!!

[skelstar]

Fuck youre a grumpy buggar poos!...whats wrong buddy...no road-legal bike?

[Postie]

He secretly wishes he had a Honda, I've seen bits of Hondas at his house, then I took a peak in his room and saw the whole place covered in posters of Hondas, SP1's, Repsols, a Naked Dani Pedrosa in a rather exposing pose across his GP bike...... the list goes on

[skelstar]

Postie, this is the reason we sent you in there. Now, where are the spy pics we asked for?

[cowpoos]

Fuck youre a grumpy buggar poos!...whats wrong buddy...no road-legal bike?
no........... :(

[HDTboy]

If your engine is still in bits, swap the pistons out for NC30 pistons, they raise the compression ratio slightly making the engine feel a bit more crisp. My NC23 has them in and I've not had any problems with anything hitting

[COP_B8]

Since last time I have repainted the engine gloss black as I did not like the matt black, and got it back in the frame, which was also repainted on the inside, around the head stock etc.... the main parts to the frame just need to be repolished now, also looking at weither I can mount the exhaust under the seat, my mate is going to popp over in soon and see weither he can modify the pipe to come up there without too many bends otherwise ill just put it back normally.

Just gotta get the wheels polished now then I can start putting brakes, suspension, wheels back on properly and the part im most dreading the loom back in.

[toymachine]

the part im most dreading the loom back in.

Geez mate I know how you feel... i'm dreading the same on my VFR.

I put tags on wires to try help but tbh alot of it's going to be trial and error.


Nice work :D

[bugjuice]

yeah, the loom is the fun part..
I rebuilt a bike I bought that had already been stripped down to nothing, so I had to learn everything with that as I was going. The best way I figured was to start at the battery terminals and just find the plugs while filtering it thru the frame.. just remember not to make anything too permanent just yet..

[COP_B8]

Geez mate I know how you feel... i'm dreading the same on my VFR.

I put tags on wires to try help but tbh alot of it's going to be trial and error.


Nice work :D

Yeah, everywhere wire and plug on the bike has a tag and number on it, and ive drawn a key and map to plug it back up right hopefully, so it should just plug straight back up........insert tui ad........yeah right

[COP_B8]

Almost done, most bits are back together, engine, subframe, lights, loom, front suspension etc... and fairings are getting painted at the moment, half are done.

Photos are a bit crap so ill put more up tomorrow.

If anyone has a track bike and wants braided lines in trade for standard ones PM me, as i cant be fuct trying to get them certified for the road.

[COP_B8]

The colour of the fairings is a little bit darker than the photos, bottom half of the side fairings will be white aswell, and then need to get some decals made up. Swingarm and wheels are going on today, then should be ready soon!!!!

[bugjuice]

gone for the lowered look.. nice :niceone:

lookin good

[COP_B8]

gone for the lowered look.. nice :niceone:

lookin good

thought it might give it better handling, speed bumps may become a problem tho :yes:

[HDTboy]

Almost done, most bits are back together, engine, subframe, lights, loom, front suspension etc... and fairings are getting painted at the moment, half are done.

Photos are a bit crap so ill put more up tomorrow.

If anyone has a track bike and wants braided lines in trade for standard ones PM me, as i cant be fuct trying to get them certified for the road.

I don't know if NC23 ones will fit, but scracha might be interested

[R6_kid]

is that the purple POS that the lube warrior used to ride? Looking good if it is! Personally i would stay away from polished parts unless you like polishing after every downpour or misty morning. Guess its a personal choice. looking forward to the final outcome!

[COP_B8]

is that the purple POS that the lube warrior used to ride? Looking good if it is! Personally i would stay away from polished parts unless you like polishing after every downpour or misty morning. Guess its a personal choice. looking forward to the final outcome!

Thatd be the same bike. yeah the polishing is a bit of a nightmare, have had some of the polished bits painted black, just trying to decide on the wheels now kinda not keen on keeping polished ones clean so am thinking of either just black or white with blue trim around it.

[Bonez]

no........... :(BUY A HONDA!!!

[DEATH_INC.]

Looking good :niceone:

If anyone has a track bike and wants braided lines in trade for standard ones PM me, as i cant be fuct trying to get them certified for the road.
Is that a nc29? I'd be keen if ya still wanna do this...

[COP_B8]

Looking good :niceone:

Is that a nc29? I'd be keen if ya still wanna do this...

Yeah its an NC29, give me a PM and we can sort it out, you do realise they do not have the correct markings to make them road legal without certification? ...or something like that so ive been told???

[COP_B8]

Almost done!!!!!
-Clutch
-Exhaust
-Fairings back on
-Make sure everythings tightened up
-Fill with Oil, Water, Fuel, Brake Fluid
-WEDNESDAY NIGHT RIDE!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

[scracha]

I don't know if NC23 ones will fit, but scracha might be interested

Indeed scracha is interested

[COP_B8]

Just putting the last bits on today and tomorrow! See you at the TWCNR hopefully.

[COP_B8]

Okay, just a few loose ends to tidy up now;

- Decals to go on
- Front Blade, Mirrors and Indicators
- Oil and Coolant

Almost there!!!!!!

The colour actually looks a bit darker in the day!

[COP_B8]

Better Pic

[peique]

Looking good, nice job! :niceone:

[limbimtimwim]

Man, you really will be cop bait in that neon blue terror..

[COP_B8]

Man, you really will be cop bait in that neon blue terror..

haha....never, ive learnt my lesson, no more speeding, over/under taking, lanesplitting, dangerous driving etc... and i even removed my number plate flippy thingy...

[COP_B8]

All done, just gotta put a few decals on it now to break up a bit of the blue.

[COP_B8]

..........