CBR 600 F2 project - pic heavy

Hello,

As suggested by Tango this is my project thread, time will tell if this project actually gains any real traction or if i spend my time riding (because its more fun) or crying (because I just cant get it back together again) but hopefully it is going to be some success.

Having been away from bikes for 5 years I finally got fed up and made an impulse ebay purchase. As it turns out the little CBR600 F2 isnt all that bad and a great ride.

After blowing up the clutch on the second ride (it actually exploded) it has had a new clutch, oil change, chain tighten, suspension set up, coolant flush, deep clean and some general tlc.

this is how the bike looks now:

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR600%20F2%20Start/CBr600F2Right_zpse9a4abd0.jpg

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR600%20F2%20Start/CBR600F2Left_zps53074f7b.jpg

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR600%20F2%20Start/Front_zpse2f99979.jpg

the issues i have found with it so far are:

1. exhaust, its blowing because two of the splines have been pushed out. After removing it i could see the baffles had been bent in the same place which is either pressure or possibly someone had jammed a screwdriver or similar into the exhaust (explains the forced out splines)

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR600%20F2%20Start/Exhaust_zps2c0ca7d0.jpg

2. running a little rough, yet to change the plugs but would benefit from a carb clean and balancing

3. chain in bad condition general wear and tear. Its a 1993 so I shouldnt expect too much but boy some people just dont give a damn

4. horrible very high pitched vibration which gets worse at high revs. It is probably explained by one of the above or all of them but yet to do a static test to see if its transmission or engine based

5. general damage to plastic, nothing terrible but it needs work.

To add to the challenge I live in a property on a farm (I don't own the farm) and have no where in doors or dry to work on the bike. Whilst i have enough parking for 15 cars there is no cover so any work is usually limited because i have to get the majority of the bike back together again.

This week will be cosmetics because its easy and makes me happy I will applying some vinyl wrap and replacing front indicators as well as continuing with the degrease.

Gimme a shout later mate. I can help with most of those problems.

All the pics are broken and I can't view them on my iPad

How strange,

I have used photobucket and copied the IMG link, the pictures show on my devices but if someone could tell me if I am doing it wrong that would be great.

I'll try using the HTML link, these arrived today

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr600%20parts/B8BA88F6-B023-4C6A-9965-7188A6EAF261_zpsmec6fadx.jpg

all the pics show up fine here using ie and normall format of the forum

All the pics are broken and I can't view them on my iPad

It's that Ipad crap again....I can view them ok in Firefox..lmao

Hmm I'm viewing on tapatalk

I bought one of these brand new in '93 in a rather fetching black grey and pink shellsuit inspired colour scheme.

It looked great 20 years ago honest.

I bought one of these brand new in '93 in a rather fetching black grey and pink shellsuit inspired colour scheme.

It looked great 20 years ago honest.

oh damn I had a shellsuit that colour !

I have just turned 30 and the bike looks better than I do so it one up over me.

ok, so along with the maintenance that has raised its ugly head I have dreams of an exhaust. I always believe if you are going to do something then you should make its as perfect as you can.

with that in mind I am looking for some opinions on what to do with the exhaust.

Below are some pictures that have elements of things I really like. However, I understand how old this bike is and I am not trying to make it look crazy nor am I interested in trying to mate new CBR plastic to make it look newer than it is. I like the shape of this bike but this slip on is rubbish and I dont like the usual f2 look like this picture with the peashooter.

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR%20exhaust%20ideas/HondaCBR600F94_zps3c70516c.jpg

Now I could go short and fat like this, I really like it but I do cover a lot of miles when I ride so it would be nice not to go deaf (that said how it sounds is more important than the headache).

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR%20exhaust%20ideas/Mototaubate-HondaCBR600F_alta_3_zps25bd6cc8.jpg

the next look is under seat. If you scroll up you will see this isnt easy but it could be achieved without too much modding. If the rear light light, blinkers and plate were moved down onto a fabricated mount (I want to do a tail tidy anyway) then something like this isn't too much of a pipe dream (optimism hey)

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR%20exhaust%20ideas/scorpion-exhaust_stealth_honda_cbr600rr_09-13_on-bike-diagonal_zps299c9ae7.jpg

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR%20exhaust%20ideas/cbr600_zps092ae618.jpeg

or it could just be more straightforward but a little interesting like this classic.

http://i874.photobucket.com/albums/ab307/JDHunter83/CBR%20exhaust%20ideas/Honda_CBR_600_Steel_Frame_A16_Twin_High_Level_Exhausts_-_Special_zps84236273.jpg

Clearly these pictures are not mine so credit goes to whoever they belong to.

I would really like to hear your thoughts to get a starting point and I know the ultimate design will depend on the talent of the person who does this (Cough MegaWatt Cough) and how deep my pockets are .

I can make whatever you can imagine Jamie. These are examples;

http://i145.photobucket.com/albums/r240/megawattblade/Exhaust%20stuff/IMAG0394-2.jpg

http://i145.photobucket.com/albums/r240/megawattblade/Exhaust%20stuff/IMAG0428.jpg

http://i145.photobucket.com/albums/r240/megawattblade/Exhaust%20stuff/IMAG0540.jpg

http://i145.photobucket.com/albums/r240/megawattblade/Exhaust%20stuff/IMAG0394-1.jpg

http://i145.photobucket.com/albums/r240/megawattblade/Exhaust%20stuff/IMAG0464.jpg

I do struggle with long tapers and hexagonal cans, but most things are do-able, given enough time and cash!!!

I'm off to sell a kidney !

ok update on my rear end

This actually relates more to my other post "transmission clunk" which I will update with our findings as well.

I arrived again at Megawatts abode and with coffee in hand quicker than the time it takes to boil a kettle (I dont know how he does that). we put the bike back onto the centre stand and yes its still doing the horrible clunk after the manual CCT installation (that was a long shot anyway).

So we slackened off the rear wheel and pushed it forward to check every link in the chain with a pair of grips. The mantra (full motion and don't rush it) instilled in my head every link was checked and nothing found.... Groan !!

ok the next step was to remove the rear wheel

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr600%20parts/42505613-c198-4dad-ad42-3eecb2531ef9_zps671693b3.jpg

Cush drive check and all fine, rear sprocket good and attached. Spacers were fine etc....

Then a breakthrough, Megawatt found both the bearing had seized but the the sprocket one was fine. Neither bearing would turn with a thumb in them, it did not feel like it would budge.

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr600%20parts/A81295F8-45DE-4742-9FF6-099466A105A6_zpsoacbhkpi.jpg

So a new pair of bearings were sourced from a local dealer at £14 for the set

Then we had the ceremonial handing over of keys.... Megawatt is a busy person with a social life far my interesting than mine and he had to go so he gave me the keys to the kingdom and a lift home (amazing). This was very exciting and hugely generous but also embarrassing that I have visited him twice and been driven home twice .

Anyway I jetted back and took the opportunity to give the rear end a deep clean.

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr600%20parts/254A1F88-5B6E-488E-9E27-E15F1A929226_zpskgbref2b.jpg

^ nice and shiny

So the journey continues, I suspect the natural thing to do now is remove the rear swing arm. I was planning on spraying it eventually but when an opportunity presents itself you should take it .

So another amazing day and what can I say but a huge thank you to Megawatt for teaching a mechanically challenged person how to stand on his own two feet and for being so generous about allowing me to take up so much room on his driveway and garage (the bike is still there in many bits).

this is the manual CCT unfortunately there is no colour choice.

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr600%20parts/771A10F4-A84A-4A0E-8541-3B7585E95B16_zpstfubowcq.jpg

The rust spot is next to be dealt with.

ok update on my rear end

Giggidy

Sorry, couldn't resist, you left it... wide open!

It was intentional .

Is it just me that tries to see how many innuendos I can get past people in the work day ?.

It was intentional .

Is it just me that tries to see how many innuendos I can get past people in the work day ?.

Nope haha

ok so a bit more of an update on progress on what is becoming more of a project.

The new rear bearings were installed by Allan with the aid of a freezer and boiling water everything was nice and straight forward. After an education on setting alignment we realised that people count differently up north to down south (every time we came up 10 half turns out on the adjusters).

After messing around with the wheel and a crappy weather preventing riding it was time for something more interesting so we looked at some exhaust options.

After the crappy old remus can was removed we found the link pipe had a baffles in it and was much larger than the standard...time to test.

At 4k rpm in this video it sounds quite mean but anything past that might "attract the wrong attention" as Allan puts it so the old can goes back on whilst I think about how the exhaust should look and sound.

As you can hear in the previous post the bike wasn't all that happy at tick over so it was time for a carb balance.

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr%20600%2026-1-14%20-%20carbs%20/BF53CB83-2950-4297-8078-040EEA102344_zpsksxtnjln.jpg

^ The bike after seat and tank removed

With the air filter and top cover removed we still couldnt find the throttle adjusters so we removed the bottom housing and bell mouths

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr%20600%2026-1-14%20-%20carbs%20/C212B780-3194-430C-9CBA-22025974FEDB_zpsavcdfoto.jpg

And found the throttle adjusters

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr%20600%2026-1-14%20-%20carbs%20/6C36DB0E-5D3C-4B3E-AD15-FB5750035A25_zps2upf8dft.jpg

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr%20600%2026-1-14%20-%20carbs%20/C72DCE69-7174-49D7-95A4-8C9D8D9FF903_zpsjw305lpb.jpg

At this point I start to get nervous (only because of complete lack of knowledge) and things were getting serious so the kettle was moved into the workshop and with my mentors cool composure my nerves were settled .

Balance restored we start to remove the nuts for the vacuum pipes which was much more awkward than it ever should have been and involved 3 extension bars, a UJ and a lot of cursing but finally they were removed and the pipes connected.

This video is about half way through the balance, I stupidly did not shoot one before the balance but the four levels looked like a graphic eq on a death metal track so this was quite an improvement:

http://www.youtube.com/watch?v=XiZUixi65U8

you can already hear how much happier the bike is on tick over.

after some more adjustments they really started to come into line:

I am now starting to really notice the difference on idle, again not perfect but sooooo much better.

http://i874.photobucket.com/albums/ab307/JDHunter83/cbr%20600%2026-1-14%20-%20carbs%20/47722F35-79D9-4F54-9AEC-62853AD84650_zpsbvobibbu.jpg

As well as actually doing some work I had a tour of the local bike stops (haven't lived here long) and the official hidden "test road".

With the bike in pieces and eyes straining to see it was time to call it a night.

And that is where we will leave it for tonight kids. I have lots more videos which I will add to this thread when I can get them uploaded.

Apologies for the rubbish quality and timing of the pictures and photos. I didn't really start to think of getting good shots until I started posting so if this is interesting to anyone I will start to get some decent pictures and videos.

Time for another quick update I think.

So it turns out the tapping noise was a header gasket leaking (apparently the only way I could find this out was by burning my finger prints off !!). After trying to nip them up it was time to take them off and replace the gaskets.

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/FD790841-905D-434D-A8EC-FADF6C05EFE4_zpszzks5ql8.jpg

What a load of *&^*

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/5BF25F2C-D7EE-4619-89F4-B9D061E2E814_zpseqekn3oh.jpg

As the headers were off they may as well get a good blasting with the drill / wire brush combo.

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/0B4676DD-A0EA-4F7A-A865-829A053151DA_zps70hqk4bq.jpg

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/C45BCDCA-4097-4A07-94CF-B1CFB0838586_zpsnvdwza5n.jpg

New gaskets

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/4075B359-C3C6-4535-9EF0-E254F1203126_zps8s7zwg5c.jpg

Unfortunately the stripping routine opened up a couple of tiny holes right at the joins . Time to find a friend who is brave enough to risk blowing the hole bigger when welding . If it all goes wrong then it will be a set of stainless headers.

instead of just trying to weld the holes closed which wont work it will just make them bigger if not very carefull use small plates of steel and tack onto the good metal futher down the pipe each side then dress it onto the pipe as you slowly weld it up worked on my 750 honda and ended up putting over 9 patches on that set of pipes

I reckon stainless headers will be ordered very soon. Followed by a one off "silencer".

here we are then.

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/cbr600-cbr-600-exhaust-downpipes-frontpipes-fm-fw-91-98-218-pekm336x238ekm_zps304d01b9.jpg

this might be getting out of hand... I think i have an addiction, can I get help for this ?...

ordered today at 14:00 should arrive tomorrow some time.

instead of just trying to weld the holes closed which wont work it will just make them bigger if not very carefull use small plates of steel and tack onto the good metal futher down the pipe each side then dress it onto the pipe as you slowly weld it up worked on my 750 honda and ended up putting over 9 patches on that set of pipes

thanks, it was beyond my talent and my friend was a little unsure so I opted to buy a set of stainless just in case he burnt a hole through them.

A few more pics of the stainless system, again using the garage of sir Alan I'll fix it for staging.

These are the new pipes next to the old. The old pipes still have the rather large link pipe with baffles on it which is why they are longer and a seemingly different angle

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/C3DB3620-C92E-4BEC-A54A-7B4FFFE6AE51_zpsc8xcjhde.jpg

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/A689B912-A740-4525-90B0-35912A7A59BA_zpsfvurmfda.jpg

I was also lucky enough to pick up a triangle dan moto can for an absolute bargain

http://i874.photobucket.com/albums/ab307/JDHunter83/exhaust/_12-2_zpsd8c427e4.jpg

unfortunately the link pipe had been hacked and after cutting down to make good it was just too slack for a good fit. not to worry alan and his garage of wonder jumped to the rescue and we now have a connector on order which should allow a tight fit without a gasket.

Unfortunately there was a consequence of all my new shiny items. When I started the bike it sounded rough and had a horrible mechanical type noise that sounded like valves. Now it hasn't been started after the carb balance and we haven't been anywhere near the valves so my new mate and me are convinced that it is just misfiring as the new pipes are almost straight through. When the new connector pipe arrives we can take it all apart again for another carb balance. Hopefully this will help resolve the issue but may not completely so there may be re-jetting on the horizon!, I really hope this isn't the case, it would be nice to just ride it for a while now (plus I didn't intend on throwing money at this straight away).

Anyway, onwards and upwards !!