VFR800 VTEC overhaul

[zRoYz]

The way I have changed my mind about what I’m doing with my VTEC has been a saga in itself, a while back some might remember my bike with a RC51 front end. Well that was removed & sold off due to my intent to sell off my VTEC. Mr Honda hasn’t done there later model customers any favors by discounting the VFR to a point you would be silly to by one secondhand. I do like my VTEC (except for the VTEC valves for service but not what they do) so because I didn’t feel the need to give it away I decided to tinker with it instead AGAIN.

I just happened to have a 2005 R1 front end that I had started to gather parts for to install on my VFR750. Now with what I had learnt from my RC51 install I knew the geometry I needed to setup the R1 forks & this is where I changed a few things & found out some things which you do when you can’t find anybody that has done same thing. I used a lower triple clamp from a CBR929/954 because there easier to obtain & if you do need in a hurry new due to mishap there $390 new from Honda where the SP1 is a mind blowing $790. I then matched this with the normal CBR929/954 upper triple.

This is where I made a mistake because I’m using Convertibars which mount under top triple clamp because R1 forks are allot shorter than RC51 & I knew there wouldn’t be enough fork to mount clipons above top triple. Well due to fork height I new works from RC51 install I couldn’t slide forks up through triple claps far enough due to Convertibar clamp fouled on fork leg where it starts to tapper thicker. I was able to solve this problem by using the SP1 upper triple clamp which is flat not gullwing & allowed for forks to move up to required length.
Now because I can & bike was off the road I decided full service was needed due to 45000kms on the dial so valve inspection (this is a story in itself but the things I found & the time it took make me laugh when I read complaints about bills, this job is as bad as changing plugs on a V12 Jag). I also took the time out to do some housekeeping so just for the record bellow is list.

Pair valve complete removal (was just blocked off before)
Valves shims 5x VTEC, 3x NORM
Balance starter valves (I did this not that long ago with a borrowed set of gauges which I think were out because I bought my own set of quality ones & starter valves were way out & for the record bike was set to 1200rpm when I started & increased to 3000rpm when finished so had to back off idle big time)
New plugs
R1 front end install
Delink brakes, braided lines front/rear
Fit Motad catless headers
Paint wheels
Paint duct tail
Fit billet fuel cap, oil cap, foot pegs

With everything I have removed I would est I have saved 15kgs off the weight of the bike but will go to weigh bridge to find out very soon as bike is ready to rock after 2 months mainly waiting for parts. Only thing left to do is dyno remap & I'll be a happy camper.

I will post some pics very soon because this post is worthless without them.

[Kat00]

Sounds like a huge job, more patience then. Good luck with it.

[Johnny]

Pair valve complete removal (was just blocked off before)
Valves shims 5x VTEC, 3x NORM
Balance starter valves (I did this not that long ago with a borrowed set of gauges which I think were out because I bought my own set of quality ones & starter valves were way out & for the record bike was set to 1200rpm when I started & increased to 3000rpm when finished so had to back off idle big time)
New plugs
R1 front end install
Delink brakes, braided lines front/rear
Fit Motad catless headers
Paint wheels
Paint duct tail
Fit billet fuel cap, oil cap, foot pegs

+ Get back bling bits off Hayden :lmao:

Sounds very impressive and well done to you, and yes, I know and understand exactly what you mean about new bike prices falling to a point where you either end up giving yours away, or keeping it, amazing but true.

[ST Kurt]

What a big job; well done. :beer: Can't wait to see it on the road.

Your constant tinkering is inspiring me to get into all sorts of trouble. I'm thinking of starting with essentials (replacing discs) then servicable items (bearings) and working up to head stock bearings and valve clearences.

For the vavles I am mentally preparing to have the bike off the road while waiting on the shims I need (after measurement). I have a firend who has offered his day to work on it with me (a big call).

Prior to attempting this, I am reading, re-reading and re-reading the workshop manual. I have researched other peoples comments experiences. Then I plan to re-read the workshop manual some more before I place a spanner near the bike.

[BART]

Good one Roy...... this is the stuff I wish I had the mechanical aptitude & patience to do. Often think about trying something like this and then I wake up.

Can't wait to see the photo's.

[zRoYz]

Quick pic thats not real good, have to wait till Birdman comes over with his cam.

First test ride quick squirt around my local test track & she will now lift in 4th when before it was lucky to lift in 2nd up a hill, no flat spots & instant throttle response so you could say I'm a happy camper & all the bloody work was worth while.

http://img402.imageshack.us/img402/5893/vtec002qv1.jpg (http://imageshack.us)

[zenodamper]

....this test track include Hillcrest ave, or the lovely chicane on Truman/Rickard? - R1 wheelies and slides whilst banked over when the rear unloads over that - very dramatic!

[ST Kurt]

Yeah, it's alright......



:) seriously though it looks good, glad you're happy with it

[Falco]

she will now lift in 4th, no flat spots & instant throttle response

Kirby, are you reading this..............:n:


Well done Roy, time to play now ey.

[Johnny]

she will now lift in 4th
A weapon disguised as an old mans bike :mod_smilie_rockwoot


Have taken one of them for a good longer ride, I see where they get the tag "old mans bike", probably due to comfort and ease of ride, but so missleading, more than capable to play hard, this on a stock one, can imagine this one with all that time invested in it :)

[zRoYz]

A weapon disguised as an old mans bike :mod_smilie_rockwoot


Have taken one of them for a good longer ride, I see where they get the tag "old mans bike", probably due to comfort and ease of ride, but so missleading, more than capable to play hard, this on a stock one, can imagine this one with all that time invested in it :)

It's a old mans tourer because I'm a old man & like to ride at a old mans pace :) the CBR1000RR for track kills me after just 20mins so I like the slow lounge chair for the road :)

[Mrs Mozz]

Looks VERY nice zRoyz,I love the wheels:ayyy:
Job well done!

[zRoYz]

Looks VERY nice zRoyz,I love the wheels:ayyy:
Job well done!

thank you but did I ever tell you I hate you because you live so close to the Oxley, but also luv you because you must be one super intelligent human as you also know a nice color when you see one :)

just buy chance you wouldn't know a Andrew Q, wife name Tony buy any chance who lives your way?

[jace]

Hi Roy I've been Busy in my garage too...all I will say is be prepared to see yellow & lots of it...hehehe...:mod_smilie_rockwoot

[zRoYz]

Hi Roy I've been Busy in my garage too...all I will say is be prepared to see yellow & lots of it...hehehe...:mod_smilie_rockwoot

thought you you would have been buzzy doing other things since you wedding, but the way congrats.

I also have been buzzy training our families newest member 12 week old lab, god he chews everything & I can't leave anything out within chewing distance, but as you know he's worth it in the end.

[jace]

thought you you would have been buzzy doing other things since you wedding, but the way congrats.

I also have been buzzy training our families newest member 12 week old lab, god he chews everything & I can't leave anything out within chewing distance, but as you know he's worth it in the end.

Haha,Ive been busy doing alot of things since we got hitched...:p

Congrats on your pupy,Labs are fun to train,they love learning new things,just promise you will not over feed him like 90% of Lab owners do.....or he will cost you a fortune in vet bills as he gets older...

[zRoYz]

Haha,Ive been busy doing alot of things since we got hitched...:p

Congrats on your pupy,Labs are fun to train,they love learning new things,just promise you will not over feed him like 90% of Lab owners do.....or he will cost you a fortune in vet bills as he gets older...

Off topic but it's my thread so doesn't matter :eyecrazy:

yes we have already started to limit his food as there a eating machine, my rotty didn't even eat like this. vet has already said to limit the food early because he will grow to fast too soon, he is also going to be a big lab anyway being male & his father is very large.

I can't leave my bikes out at the moment because he thinks there chew toys & has already had a feast on my pocket bike but he is learning what he can chew & what he can't as they are a very smart dog maybe to smart.

He started this big
http://img155.imageshack.us/img155/2261/dogxa6.jpg (http://imageshack.us)

He is now this big 16 weeks
http://img175.imageshack.us/img175/8733/labkf2.jpg (http://imageshack.us)

[jace]

Haha..nice Dog,very nice....:ayyy:

[Johnny]

It's a old mans tourer because I'm a old man & like to ride at a old mans pace :)
Well maybe/hopefully one day I can get that old man pace thingy happening :o trying though, getting old bit Im winning :p

edit..
Oh and nice pup, congrats :)

[Turtle]

Labs are cool dogs Roy.......Good one Mate.....:) Ask Noel he has a little Pussy ass Pomeranian, (named Roxy) man that Dog is GAY......

[Mrs Mozz]

thank you but did I ever tell you I hate you because you live so close to the Oxley, but also luv you because you must be one super intelligent human as you also know a nice color when you see one :)

just buy chance you wouldn't know a Andrew Q, wife name Tony buy any chance who lives your way?

Hahaha oxley is fun as a pillion, I havent ridden it by myself yet but hoping to get a few practice runs before you all come up:ayyy:
No dont think I know this Andrew but If he rides there is a chance that Mozzie might

[Birdman]

+ Get back bling bits off Hayden :lmao:

Sounds very impressive and well done to you, and yes, I know and understand exactly what you mean about new bike prices falling to a point where you either end up giving yours away, or keeping it, amazing but true.

nope he doesnt need his bling bits back hes got enough:)

[Birdman]

Quick pic thats not real good, have to wait till Birdman comes over with his cam.

First test ride quick squirt around my local test track & she will now lift in 4th when before it was lucky to lift in 2nd up a hill, no flat spots & instant throttle response so you could say I'm a happy camper & all the bloody work was worth while.

http://img402.imageshack.us/img402/5893/vtec002qv1.jpg (http://imageshack.us)

lookin good mate, you have to let me paint my SP2 wheels the same color though :ayyy:

[Birdman]

Labs are cool dogs Roy.......Good one Mate.....:) Ask Noel he has a little Pussy ass Pomeranian, (named Roxy) man that Dog is GAY......

thats not a dog, its a long haired rat that cant get its tail down:lmao: :lmao:

[zRoYz]

thats not a dog, its a long haired rat that cant get its tail down:lmao: :lmao:

no the rats live in the house :lmao:

[zRoYz]

lookin good mate, you have to let me paint my SP2 wheels the same color though :ayyy:

I don't see anyway of stopping you, but not a problem because blue is best as we both know :ayyy:

[Birdman45]

see you on the 28th mate, may need a hand with some stuff though, like getting the bike on the dyno etc, for obvious reasons. LOL

[zRoYz]

see you on the 28th mate, may need a hand with some stuff though, like getting the bike on the dyno etc, for obvious reasons. LOL

Thats a given, what you think I would be siting outside twiddling my thumbs, you would have to tie me up to not be close buy & I do take instruction well (unless your my wife then it's me no understand). Do you have a preferred time & don't forget to let me know address.

[Birdman45]

sorry about today mate, I got the reply to my sms from a few days ago at 6am this morning that he ain't there. He said 2 weeks but that was from xmas I'm guessing, confirming with him though. Normall it wouldn't be a drama, as I have keys etc, but in my condition at the moment, I can't open everything up that needs to be and move all the bikes etc. let you know asap and sorry again.

[zRoYz]

sorry about today mate, I got the reply to my sms from a few days ago at 6am this morning that he ain't there. He said 2 weeks but that was from xmas I'm guessing, confirming with him though. Normall it wouldn't be a drama, as I have keys etc, but in my condition at the moment, I can't open everything up that needs to be and move all the bikes etc. let you know asap and sorry again.

mate it's a shock your even working, I'm not stressed about it at all as got your txt early enough to go back to bed :)

just let me know when your right & we will do it then, after hours is also fine with me.

RoY

[triumph]

mate it's a shock your even working, I'm not stressed about it at all as got your txt early enough to go back to bed :)

((((just let me know when your right & we will do it then, after hours is also fine with me.))))

RoY
roy you sicko does your wife know about this .:lmao: :mod_smilie_bj:

[zRoYz]

roy you sicko does your wife know about this .:lmao: :mod_smilie_bj:

Yeh she's coming..............in a minute :lmao:

[Birdman]

mate it's a shock your even working, I'm not stressed about it at all as got your txt early enough to go back to bed :)

just let me know when your right & we will do it then, after hours is also fine with me.

RoY


might have to join you in the dyno, just as soon as i balance throttle bodies insert the K & N and change the oil, bike really needs a new map

[zRoYz]

Thank Birdman for the pics enjoy :ayyy:

http://img119.imageshack.us/img119/6980/vfr1009rs4.jpg (http://imageshack.us)
http://img406.imageshack.us/img406/3214/vfr1011sz4.jpg (http://imageshack.us)
http://img406.imageshack.us/img406/7617/vfr1014hv8.jpg (http://imageshack.us)
http://img406.imageshack.us/img406/5797/vfr1020lr9.jpg (http://imageshack.us)

[zenodamper]

good stickers! :lmao:

Gonna do F4i in a mo' (right after Zee's RR-3)

[zRoYz]

good stickers! :lmao:

Gonna do F4i in a mo' (right after Zee's RR-3)

Lucky or I'll post your pic up slacking off at the computer in the workshop :lmao:

For anybody like me who needs reading glasses the stickers zeno is referring to, say Zenodamper as the R1 forks internals are a special designed by him using me as a test monkey. Think he might be happy with how there working because I am :ayyy:

[MadHatter]

looks good roy

[Bigdog]

I'll say. Looking very good matee!

[Turtle]

Can you get one of those seat cowls that goes over the pilly section of the seat ??? It would look awesome with a Kicked up tail ......

[zRoYz]

Can you get one of those seat cowls that goes over the pilly section of the seat ??? It would look awesome with a Kicked up tail ......

Yes I just haven't put it on & it's black :ayyy:

[Birdman]

Lucky or I'll post your pic up slacking off at the computer in the workshop :lmao:

For anybody like me who needs reading glasses the stickers zeno is referring to, say Zenodamper as the R1 forks internals are a special designed by him using me as a test monkey. Think he might be happy with how there working because I am :ayyy:


Ahhhh thought you looked like a test Monkey :lmao: :lmao: :lmao: :lmao:

oh and yes the fork must be working well judging by the way your throwing the bike around now !!!!!

[kirbster]

Kirby, are you reading this..............:n:

I don't need to be - he is putting a RC51 front end on mine shortly once I gather the last couple of bits for it... :ayyy:

The only downside is this little project will clean me out financially bike wise for quite some time. So if I see you guys at the track over the next few months it will be as a spectator :mad:

[triumph]

roy will let you ride his track bike .

[Birdman]

I don't need to be - he is putting a RC51 front end on mine shortly once I gather the last couple of bits for it... :ayyy:

The only downside is this little project will clean me out financially bike wise for quite some time. So if I see you guys at the track over the next few months it will be as a spectator :mad:

maybe ill even give you a session on a real bike :ayyy:

[zRoYz]

roy will let you ride his track bike .

I have already offered the only catch is he has to do different days to me as we both can't do A & 2x sessions in a row cooks the tyres to much.

[zRoYz]

I don't need to be - he is putting a RC51 front end on mine shortly once I gather the last couple of bits for it... :ayyy:

The only downside is this little project will clean me out financially bike wise for quite some time. So if I see you guys at the track over the next few months it will be as a spectator :mad:

yeh & when you come over with the remaining parts allow some time to stay so you can clean & polish your Staintunes there filthy.
valves done
cam tensioner done
headers fitted
oil/filter done
general service done
penske ordered
link brakes removed (parts better come or you wont be going to snowy now)
standard front removed
new tapered bearing head stock races installed
coolant flushed & renewed
should get wheels this week from painters
zeno promised forks rebuilt by next weekend

I WANT PARTS :eyecrazy:
p.s your not doing bonang dirt part on this bike or your not having it back :lmao:

The only reason it's costing so much is you keep buying bling & this is from a person that told me when I bought my Pazzo's long ago there a waste of money....how things change.

Also keep away from my ute & I'll ride your bike outside when finished :cursing:

[Birdman]

yeh & when you come over with the remaining parts allow some time to stay so you can clean & polish your Staintunes there filthy.
valves done
cam tensioner done
headers fitted
oil/filter done
general service done
penske ordered
link brakes removed (parts better come or you wont be going to snowy now)
standard front removed
new tapered bearing head stock races installed
coolant flushed & renewed
should get wheels this week from painters
zeno promised forks rebuilt by next weekend

I WANT PARTS :eyecrazy:
p.s your not doing bonang dirt part on this bike or your not having it back :lmao:

The only reason it's costing so much is you keep buying bling & this is from a person that told me when I bought my Pazzo's long ago there a waste of money....how things change.

Also keep away from my ute & I'll ride your bike outside when finished :cursing:

:lmao: :lmao: :lmao: :lmao: :lmao:

[triumph]

so birdman when you geting a real bike . :lmao:

[Birdman]

so birdman when you geting a real bike . :lmao:

i already got 3 mate and non are made out of cheese :ayyy:

[zRoYz]

so birdman when you geting a real bike . :lmao:

you have to be able to catch him on the bikes he has before you can say that :)

my next door neighbor asked me today while I was out killing myself doing the lawns who's bike was making the loud noise the day before because he said it sounded great. it's a shame you don't get the induction noise with the air box on like you do with it off while we where doing starter valve balance.

[Birdman]

you have to be able to catch him on the bikes he has before you can say that :)

my next door neighbor asked me today while I was out killing myself doing the lawns who's bike was making the loud noise the day before because he said it sounded great. it's a shame you don't get the induction noise with the air box on like you do with it off while we where doing starter valve balance.

Hmmm carbon fibre air box should fix that, i too wish it sounded as good with airbox as it did without

[kirbster]

yeh & when you come over with the remaining parts allow some time to stay so you can clean & polish your Staintunes there filthy.
Those cans are beyond hand polishing they need a machine shop. :headshake:


The only reason it's costing so much is you keep buying bling & this is from a person that told me when I bought my Pazzo's long ago there a waste of money....how things change.

Well if you're going to do a job like this you might as well do it properly...


Also keep away from my ute & I'll ride your bike outside when finished :cursing:
Things around your house hate me so no problem :hatter:

Yeah I know you will let me loose on the CBR but there is the small matter of track day cash, fuel, tyres... Plus the wife wants a new kitchen now, she is tired of waiting for her turn to spend all the money :lmao: Nope I reckon it'll be a while... :headshake:

[zRoYz]

I have polish that will clean up those cans, you just need elbow grease :lmao:

[exfirestorm]

http://i114.photobucket.com/albums/n267/exfirestorm/14012008002.jpg

I have a long way to go.

Royz have you ever contemplated removing the heat shield from behind the rhs footpeg for cosmetic reasons because motad pipework should be seen.... I am thinking seriously of doing it myself

[exfirestorm]

http://i114.photobucket.com/albums/n267/exfirestorm/02112007003.jpg

http://i114.photobucket.com/albums/n267/exfirestorm/02112007001.jpg

http://i114.photobucket.com/albums/n267/exfirestorm/02112007002.jpg

it would look sort of along the lines of this I would imagine...aesthetics vs functionality ...the bane of any back shed modifyer

[zRoYz]

Just be careful your rear brake master cylinder lines/wiring don't melt which is the main reason it's there. You may also find your boot /foot will melt as mt boot melts on the Laser link pipe which I have to do something about but only happens when I get off the bike when playing hard on the heal of boot.

[muzz]

fark there some pipe work stuffed in there

[triumph]

looks like more pipe and bike

[Turtle]

Just be careful your rear brake master cylinder lines/wiring don't melt which is the main reason it's there. You may also find your boot /foot will melt as mt boot melts on the Laser link pipe which I have to do something about but only happens when I get off the bike when playing hard on the heal of boot.

Are they the same pipes as yours Roy ???

[Turtle]

I must admit zRoYz VFR IS the ''sweetest'' VFR i've ever seen !!!!!!!!

[Birdman]

I must admit zRoYz VFR IS the ''sweetest'' VFR i've ever seen !!!!!!!!


crawler :lmao: :lmao: :lmao:

[zRoYz]

Are they the same pipes as yours Roy ???

yes they are, in fact it was exfirestorm post on ozvfr that enlightened me to the catless headers (I already had Lasers).

[zRoYz]

crawler :lmao: :lmao: :lmao:

well you seem to keep buying the same parts as me too (well equivalent for a BB).

[Birdman]

thats just because we both have impeccable tastes !!!!!!!

Hey at least i got a different helmet to try and be different even though i really wanted the same as yours

[Birdman45]

How is the bike? Sorry I didn't have time to do yours Birdman (still very weird calling someone else MY net name. hahaha) see you next weekend.

[zRoYz]

How is the bike? Sorry I didn't have time to do yours Birdman (still very weird calling someone else MY net name. hahaha) see you next weekend.

Feels good so far & vtec transition is allot smoother (not that it bothered me that much hehe) pulls like a train & I did find I didn't use vtec very often & was short shifting before 7K due to enough power. I need some corners to play with as best part of Putty sun had a escort through best section.

[Dr freedom]

http://rsxisfaster.files.wordpress.com/2007/05/scootervtec.jpg

[Birdman45]

sweet. Let ,me know how you go on the bendies. LOL

[DanOz]

Feels good so far & vtec transition is allot smoother

And it sounds great as well - I've been following you a bit closer on the way back from Wollombi to Pitts Ridge and the sound of the V4 when it ramps up, is quite unique.
:ayyy:

[exfirestorm]

zRoyz did you have any installation hiccups when installing your motad headers. In particular when installing connecting the main part of the system up to the rear header down pipes.

I did it in the end but only after I had deformed the gaskets which needed replacement. Mind you I think my problems were related to being a hamfisted mechanic rather than a problem with the part.

Could I trouble you to provide a brief blow by blow as to how you got seated the down pipes into the rest of the system during installation. Like i said, I got there in the end but i did it messily

This is what I did....

I installed the rear down pipe headers into the rear exhaust ports using new copper gaskets. I put a little rtv sealant to hold the gaskets in place while I did this. I did not totally tighten these ports at this stage

I connected the front header pipes/assembly to the front exhaust ports with new copper exhaust port washers and rtv sealant to hold the gaskets in place until i had situated the headers.
I installed the exhaust port nuts with a small amount of nickel anti seize. I didnt tighten these up very tight and I elevated the back part of the system with some occy straps while I was doing this so that the system was roughly lined up with the back header pipes.


This is where I had problems.... (This is related to my idiocy not the product)

The first time I attempted this install when I was guiding the front part of the system onto the already situated rear header pipes I deformed the soft metal sleeve type gasket so badly that I could not install the system.

The second time I did the install what i was equipped with new gaskets. I positioned the gasket sleeves onto the rear header down pipes rather than in the main part of the header system that they had been.

I spread out the opening of the main part of the system where the header pipes go into and joined the pipes together pushing the sleeve type gasket down into the join after the two pipes were together.

This works fine and there is no leaks (Thanks to the copius application of rtv exhaust sealant on the join. But my way is messy and necessitated the spreading out of the joining point of the main section of the header system.

I think that if I had two people helping me out than this job would have been much easier but I am really curious as to whether you had any problems when installing the header system and whether you used sealant on this joint and whether or not you have any slight exhaust leak from this join

I dont have any leaks but I really did struggle installing the system and a part of me wishes that I had given this job to a professional who would have installed the exhaust with no problems the first time....it was just that I never anticipated that the installation of a full system would be at all difficult....and it wasnt technically, but as I said because of my hamfistedness and me trying to force things together I initially made things much worse before they got better

[exfirestorm]

http://i114.photobucket.com/albums/n267/exfirestorm/exhaustjoint.jpg

[exfirestorm]

http://i114.photobucket.com/albums/n267/exfirestorm/02112007003-2.jpg