2007 YZF-R1 Rebuild

[fr0st]

Since I have a habit of starting projects and never finishing them this is my official motivation to get shit done thread. Feel free to hassle for updates and call me out on my weak excuses if it's not progressing fast enough

I've always wanted to rebuild a wrecked bike so I went auction trawling and found a nice (for a wreck) 2006 YZF-R1. After some frantic java updates and bid button spamming, it was mine for a reasonable $4k after auction fees. I went with a mate to pick it up yesterday and discovered there was no key, fucking brilliant work by the auctioneer not mentioning that. After a blowing a tire on the tow car we managed to get it into my friends shed where it will live until it's ridable again.

The (very loose) plan is instead of spending ~12k on a nice liter bike, I'd buy a piece of shit and build it back up as my own. I have a bad tendency to disagree with the manufacturer on how my vehicle should run, ride and look so I figured I'd start with nothing and build it back up instead of taking a nice bike and throwing half of it away.

IMG_0036.JPG

The right hand side of the bike took all the damage so the picture doesn't really reflect how much work I have to do. So far my repair list stands at -

• Fairings all round $608 ordered and paid
• Fairing stay bracket $102 ordered and paid
• Both mirrors $26 ordered and paid
• Front indicators $20 ordered and paid
• Both clip on's $85 ordered and paid
• Bar ends $15 ordered and paid
• Kill switch $105 ordered and paid
• Brake & clutch lever $42 ordered and paid
• RH headlight $150 ordered and paid
• Both air ram ducts $165 ordered and paid
• Clutch cover $310 ordered
• Rearsets $250 ordered and paid
• RH Pillion peg assembly $77 ordered and paid
• Rear indicators $140 ordered and paid (comes with lube for Yamaha's pleasure)
• Rear brake light $93 ordered and paid
• Rear fender/number plate holder $52 ordered and paid
• OEM mufflers $100 ordered
• New Keys, locks and ECU $150 ECU flash, $50 for new keys

The keys and ECU are the main problem, fortunately I found a complete set with fuel cap and pillion locks going on eBay for $650 from a reputable source. Much better than the 2.5k that Yamaha wanted
Probably a waste of time asking, but if anyone knows the previous owner of the bike so I can get the original key you will both be rewarded with much beer/spirits/someone's sister. The fuel cap and pillion seat are currently locked and I have picked a wafer lock in a long time, having keys would save a tonne of hassle.

I'm got a big shopping list to go through tonight and I'll update the list with prices when I'm done. I'm hoping I can get it back on the road for around 7k then once it's over the pits I can go nuts with the mods.
Mufflers I was thinking some Yoshi slip ons but I'm worried about going over the decibel limit at the pits, any recommendations? I can definitely find some standard ones to get it over but I don't really want to buy something twice. Maybe some steel wool and a homemade silencer could do the trick.

Tear down starts on Saturday so more pics then. If anyone thinks they can help me out with any parts on the list just shoot me a PM.

Cheers all

[Hewie]

You got lucky ... dats an 07

[DRKSIDE]

Nice buy! I had my eye on that but got a different one. What are your plans for this bike?

Do u remember how much either of those two ZX10's went for? Both were 08 models

[fr0st]

You got lucky ... dats an 07

Really?! How can you tell the difference?
Rego shows 2006 and compliance was 12/2006. The parts seem to match the 2006 service manual I have as well. I might be a little screwed if its an 07 because I've already ordered 06 fairings and ECU & Keys.

EDIT: Shit, you might be right... just tried a VIN decoder and it said 2007.

Nice buy! I had my eye on that but got a different one. What are your plans for this bike?

Do u remember how much either of those two ZX10's went for? Both were 08 models

I think I met you at the Pickles auction bidding on your ZX10. Sorry for bidding on the same bike, I felt like an ass but I kinda wanted that ZX10 as well since the GSXR went so high
The stat write off went for about 3k. The near new 08 ZX10 went for 7.8k I think.

Plans is to get it on the road as soon as possible then start modding. I'm changing the paint to satin black then do the usual performance and suspension mods like PCV, velocity stacks, full exhaust, rear shock etc.

[Hewie]

Yup pretty sure




Yamaha YZF-R1 (2007-2008) - Yamaha Motorcycle Reviews

2007 Yamaha R1 Street Ride - Motorcycle USA

Yamaha R1 News, Reviews, Photos and Videos - Motorcycle USA

[Hewie]

04-06 were the same shape

07-08 they changed to that shape .. 07s had that fairing scheme in Aus.

Sorry bud

[Halo_2]

Hewie is 110% right

[fr0st]

Well on the bright side I now have an 07 bike.... on the downside I have $1400 worth of orders to cancel...
Shit happens I guess

[kenty]

think positive, at least you can cancel them and not have to pay return postage

[Hewie]

Sorry to be the bearer of bad news mate, but at least you didnt get to the end of all your purchases before you found out.

[DRKSIDE]

I think I met you at the Pickles auction bidding on your ZX10. Sorry for bidding on the same bike, I felt like an ass but I kinda wanted that ZX10 as well since the GSXR went so high
The stat write off went for about 3k. The near new 08 ZX10 went for 7.8k I think.

Plans is to get it on the road as soon as possible then start modding. I'm changing the paint to satin black then do the usual performance and suspension mods like PCV, velocity stacks, full exhaust, rear shock etc.

meh don't worry about it such is life. I was pretty happy with how my auction ran. Glad to hear u got this one for a good price! If u bought Chinese fairings and don't have a dremel already-BUY ONE. I'm learning how 'exact' Chinese measurements are right now...*sigh* haha

[Professor Redfern]

Generally any R1 built after October or so is the next years model, becuase obviously they build them so they are ready and on the road by the start of the next year.


Yamaha always release the New models officially in September and then they can be on the road by about October. On th ebright side you have Vairable Valve intakes, and more low down power.

[fr0st]

Sorry to be the bearer of bad news mate, but at least you didnt get to the end of all your purchases before you found out.

No problem at all, I owe you a beer for saving my ass. It could have been way worse.

I went on an online shopping spree after sending a few frantic e-mails to cancel the wrong parts. I definitely feel a little better now

Just thinking out loud about my ECU problem. I figure there is 3 ways to solve it -

• Pay the 2.5k for a new ECU and keys to match (or find a donor)
• Somehow bypass the fly-by-wire throttle and put in a Microsquirt (or Megasquirt3, whatever works)
• Assuming that the transponders are just like an RFID tag, technically I could find the serial line going to the ECU and brute force it using a micro controller

I quite like the second option, I have an MS3 half running my car and they're great to work with. I need to do a little research on the engine as I think it has a magnetic crank angle sensor and another random sensor to mark the first cylinder. I don't really want to go the custom ECU because it will drag out the project a lot longer than I want. But if I have to choose between being shafted by Yamaha and putting in the MS, the MS wins.

[Hewie]

Tried Motorcycle Masters ? Morry and the lads are pretty good.

[W1LK0]

I've got a set of standard mufflers and bunch of other stuff I'd be happy to lend out as long as a deposit is left for their return.
Send me a PM with what you haven't already got coming now and I'll check the shed for you.

Whats the future mod list?

[loki kelly]

keeping my eyes out for ya, all respect to you mate for making something your own!!! theres nothing more rewarding. i will be following your thread with great interest!!

loki

[Halo_2]

http://www.carmo.nl/index.php?main_p...1351_1355_1362

[Arwon]

Why not get the ECU flashed with the YEC software and switch of the imobiliser circuit. Should cost less than $1k

[fr0st]

Good news on my botched orders, the fairings have been changed and I received a refund on the ECU & Keys. I may have to keep the clutch cover if it doesn't fit but wasting $300 isn't so bad

I think I have the ECU problem sorted. Diamond lock and key said they can cut some keys for me if I bring in the ignition barrel and a YEC reflashed ECU ($450 from the states) will take care of the immobilizer and negate the need for a PCV later on. I haven't done much research into how easy they are to tune but the base map should last me a while.

EDIT: Beaten by Arwon on the YEC, great minds think alike?

I've got a set of standard mufflers and bunch of other stuff I'd be happy to lend out as long as a deposit is left for their return.

Thank for the offer! I have a bid on eBay for a set located in Perth for $100. If I don't get them I'll shoot you a PM. They are probably a handy item to have just in case the bike gets a DPI racing sticker.

Whats the future mod list?

After the pits I'll do the suspension first. I was thinking a new set of tyres, Ohlins rear shock, braided lines, decent pads and then getting Marty Moose to adjust it all. The forks and brakes should be fine, maybe a Brembo master cylinder for a bit more bite.

Engine will just be the usual mods. Air filter, full exhaust and tune should see it fairly well sorted. Factory slipper clutch should be fine unless it's taken a beating. I might change sprocket sizes to see the difference but it's not really a priority.

For the exterior I was thinking of getting a few large sheets of carbon to play around with vacuum bagging a new set of fairings. I've worked with fiberglass weave before so I'm hoping it's kind of similar. I'll stick to my idea of having all the plastics Satin Black and then use the gloss finish on the carbon as racing stripes down the bike (kind of hard to picture at the moment).

Cheers all

[CrotchRocket]

Good news on my botched orders, the fairings have been changed and I received a refund on the ECU & Keys. I may have to keep the clutch cover if it doesn't fit but wasting $300 isn't so bad

I think I have the ECU problem sorted. Diamond lock and key said they can cut some keys for me if I bring in the ignition barrel and a YEC reflashed ECU ($450 from the states) will take care of the immobilizer and negate the need for a PCV later on. I haven't done much research into how easy they are to tune but the base map should last me a while.

EDIT: Beaten by Arwon on the YEC, great minds think alike?



Thank for the offer! I have a bid on eBay for a set located in Perth for $100. If I don't get them I'll shoot you a PM. They are probably a handy item to have just in case the bike gets a DPI racing sticker.


After the pits I'll do the suspension first. I was thinking a new set of tyres, Ohlins rear shock, braided lines, decent pads and then getting Marty Moose to adjust it all. The forks and brakes should be fine, maybe a Brembo master cylinder for a bit more bite.

Engine will just be the usual mods. Air filter, full exhaust and tune should see it fairly well sorted. Factory slipper clutch should be fine unless it's taken a beating. I might change sprocket sizes to see the difference but it's not really a priority.

For the exterior I was thinking of getting a few large sheets of carbon to play around with vacuum bagging a new set of fairings. I've worked with fiberglass weave before so I'm hoping it's kind of similar. I'll stick to my idea of having all the plastics Satin Black and then use the gloss finish on the carbon as racing stripes down the bike (kind of hard to picture at the moment).

Cheers all

just on the carbon fiber:
you know there is wet lay-up and prepreg?
the wet lay-up is the weave and resin separate, very similar to fiberglass.
lay the fabric on and paint it with the resin
Kirkside in Osbourne Park do the fabric for about $75/m
it doesn't normally need vacuum bagging either.

i use vacuum baggin for the prepreg, its annoying, prepreg is really hard to work unless you know what your doing.
you gotta keep the prepreg in the freezer and when you take it out it gets sticky and unworkable.

just my 2 cents worth, hassle Kirkside for more info or PM me about the carbon.
good luck with the build