CBR400RR - Spring Service...

[Iccle]

So after spending nearly £700 on bit to get the 'Blade through the MoT, figured now was the time to crack on and get the work done.

Day 1
Pulled the bike up onto the (lovely) Abba Stand... now where to start?


Stripped off all the fairings, bar the front piece, put safely to on side for a good clean. Managed to snap on of the fairing bolts, bloody ally crap. Phone call to make Monday morning for a replacement, maybe! (Removed hanger bracket, Drilled out snapped bolt, cleaned and remounted!)



Disassembled the front end, forks off, yoke out, bearing all seem good, if a little dry.
(Pictures to come later)

Exhaust Off... it's rotten. 7/8 studs unbolt from the engine but none snap off, Good Job.

The Hole made by jacking it up on a car jack, it's also been flattened here too...

16 Year Old Headers... seen better days.

Managed to snap a bolt in the End Can... 2 seem to be original, the snapped one is some sort of cheap knockoff.... bloody crap again! (Drilled, Tapped, Fixed!)

Cleaned up the forks with some good old elbow grease...


Dark Now, Tea Time!

Day 2
Started off today by cleaning and polishing the forks and exhaust hanger. Nice and shiney again!

In the meantime, the old man seperated the nuts from the Exhausts Studs, after left to soak over night in what can only be called "Miracle Spray" AKA Rust Shock. Once they were all seperated, we refurbed all the Nuts & Studs, almost as good as new. Tap & Dye sets do come in handle for getting the shite out of threads.

Re-Greased and Re-Packed the Bearings, nice and notch free, thankfully, rebuilt the front end, minus Wheel... set aside for the new set of rubber. Top Yoke nut had to be tightened to 105nm... fook thats tight. Give up at 90nm for fear of shreading the threads. It's already 4x tighter than when it came off!!!

Spot the canine helper!

Dropped the back wheel out... Need to get in and clean that swingarm, now I can see it.


Thread lock on the Studs bolted back into the engine, ready for the new stainless system.

Wheels given a good clean, don't want the nice man who changing the rubber to get dirty hands!

Drained the coolant out ready for replacing.

Still to do... Oil Change, with Filter Replacement. Fit new Exhaust. Change Brake Lines to HEL Stainless ones and referbish calipers. More cleaning...

[Iccle]

Day 3
Started off by going on a trip out to Iron Acton, to have a look at the Bike Hut... forgetting it's closed on a Monday... DOH! At least the old man got the parts he wanted for his pond from the Aqua Centre nearby.

Anyway, got back and did some more cleaning, polishing and cleaning. Then went to work on the brakes.

Took the calipers completely apart, gave them a bloody good clean... off to Fowlers in Bristol to get new seals and boots.


And a new set for the master cylinder...


Also borrowed Mum's car, and had to goto Honda at Cribbs Causeway for some new Windscreen Wipers... fair swap Petrol > Blades!

Day 4

Spent the day entirely on the brakes, gave everything a bloody good clean. Another trip to Fowlers, for the seals for the rear calipers. Wasn't originally planned, but though fook it... what the hell.

New Seals, Rubber Boots & Pads, with some stainless steel bleed nipples... all good to refit with the new HEL brake lines.


AndyW (from BikeTechForums) popped over and grabbed my rims & new tyres, off to fit over night for me.

I've got more pictures around somewhere, on a different camera.

Day 5
Another huge thank you to AndyW who dropped the tyres back round this evening, looking great.

All work paused for now, thanks to this beautiful arrival...


Caitlin Rose, born at 20:13 on 25-03-09, weighing in at 7lb14oz

Mother and Baby are doing very well, apart from having to stay in over night!

[w00dzy]

first of all, congratulations on the new born..

looks like your doing a good job sorting the bike out..

like the look of the stand your using.. how do you get it up on to it??

[Iccle]

first of all, congratulations on the new born..

Many Thanks

Looks like your doing a good job sorting the bike out..

like the look of the stand your using.. how do you get it up on to it??

http://www.abbastands.co.uk/" onclick="window.open(this.href);return false;

http://www.abbastands.co.uk/product_details.asp?id=1" onclick="window.open(this.href);return false;
Watch the Video, about 2/3rds down the page. Easy Peasy!

[wullvfr]

just like woodzy say's,congrats on the new arrival :D and job well done on the bike,keep it up and get it all hunky dory




william

[marty400]

Awesome Write up Iccle!

Really good see guys really into the mechanics of their bikes!
Fantastic looking NC29 BTW!


Hope the new born is doing well


Cheers
Martin

[Jolan]

Nice project and clean-up! Nice too read and some good upgrades.

Goodluck and congratz with the other project

[Iccle]

Quick Addition:

Found the data specs for the Rust Flash that I've been using on the bolts. Bloody Amazing stuff, I really suggest getting this if you have some "dodgy looking" bolts.

http://www.chsinteractive.co.uk/pdf_data/AMB6.pdf" onclick="window.open(this.href);return false;

http://www.chsinteractive.co.uk/electri ... -shock.htm" onclick="window.open(this.href);return false;

[Iccle]

Day 6 & 7

2 more days with out me doing any work on the bike, as I figured staying in and spending time looking after the missus was the best thing to do... not to mention I have a wonderful baby girl to bond with!

Day 8

Turns out my old man has got on with some extra bits of cleaning whilst I've been occupied...


The shock was caked in road dirt and oil, but is now nice and clean, however I don't think I have any room for one of those ShockTubes. I'm gonna send the guy some picutres and get his thoughts.


The swingarm was also black with crap... all shiney clean(ish) now!

The rest of the day was spent refitting the wheels, doing the new brakelines and bleeding the brakes (and new Front Mastercylinder!).

[Iccle]

Day 9
Day 9 was a fun day... probably the best day of the whole service, the weather was nice and the tasks were easy and straight forward.

First, the coolant change... Having already drained out what appears to be less then 2 litres of old yellow and brown shite, we replaced it with the nice blue stuff in the bottle on the floor.


Then we drained the oil... using an "Oil Tray" which is about 35 years old! Good ol' Castrol eah!


Cracked off the old Oil Filter and replaced it with a new one...



And refilled the bike with some Castrol 10w40 Power1 GPS Semi-Synth, which is strangly orange!!


Then it was time to fit the new exhaust system...




It was a perfect fit, no messing needed...


Should be finished by...

Day 10
Quick and easy stuff... Refit Fairings - Done, Check all electrical systems (lights, switches etc) - Done, Take for a little Shakedown run - Done.

Oops, one more thing... need to check and adjust the headlight alignment... Much fun to be had here!!