D6 Rebuild after crash

[detonation]

Well I've been putting off posting my build up as I got the feeling it's not to most peoples taste but now there's a rebuild section hey-ho I'll give it a try.

Well originally I bought my D6 for about £540 like this



After some work over the next few months

Bodywork:
eBay Grips
SV 650 Front Fairings
Bandit 600 Fuel Tap
Home made undertray with dual round tail lights
Integrated GSX 1300 R Mirrors
Carbon Wrapped tail infill panels
99 XJ 600 N Tail
Smaller Plate
SV650 Speedo Case
Quick Release Fuel Cap

Lighting:
Aprilia SR50 tail lights with Indicators integrated.
Licence Plate Bolt Lights
Brake and indicators fitted in top box reflector
SV650 Headlights
L.E.D Idiot Lights
Mini arrow rear indicators
Audi Style L.E.D side lights.

Electrics:
Manburen speedo
Voltage meter
Alarmed
Wired Headlight Permanently on
Headlight wired threw relays
Headlight cut whilst starting
CBR 600 FI Left Switchgear
eBay loud Horn

Engine:
Motad Nexus Headers

Suspension and Handeling:
CBR 600 F4I adjustable Rear Shock
20w Oil in Forks
GSXR 750 K5 Damper

Brakeing:
900 Diversion Rear Caliper





Then I lost my job so work on the bike (including maintenance) stopped but riding it everyday didn't.

Then finally in June I found a new job but in the second day was hit by a car hew changed lane straight into the side of me on a roundabout.

Result was damaged tank, paint, undertray, exhaust can, handlebars, brake and gear peddles, sprocket cover, grazed engine covers, blown fork seals, somehow wiring was damaged, fairing was ground down flat in spots, top box ended up with a flat spot, headlight scratched, tire valve was somehow ripped right out the rim ?!?!? Ain't never seen that before.

I have thousands of pics from the build before loosing my job but won't bore people with them.

My mate owed me money for rebuilding his CG 125 so he bought me a new tire and valve for my FZR rim



then my first pay check went on

Fork seals and oil
GSXR 750 K5 exhaust can
New sprocket cover
Rewiring the headlight
New brake pads all around
Fixing the undertray

I then bent the foot levers back
Made sure wheel alignment was straight

Spent next pay check on

Oil and filter
Longer side stand as bike had quite a lean on it from the CBR shock I have fitted
New bulbs all around
Sanded filled and painted the tank

So now she stands like this still in need of much work.






Well, them photos where before clear coating the tank



I also 'TRIED' to make my self more visible




I know she's still a bit of a embarrassment and needs a lot more work.

Hope to clear coat everything else next week.

Front mudguard will be getting replaced when I put a FZR front end on it so won't bother painting that.

Unfortunately I have found a tiny pin hole in my down pipes this week so I'll be needing to buy a new system aswell, I'm thinking about one of them delkevic systems on eBay

[HRHpenfold]

No bore us with more pictures, there is nothing more boring than only a few pictures,

What's a manburen speedo?

I quite like it, it's different!

[detonation]

The manburen is a small digital speedo that's sold as both a pushbike speedo and a motorcycle & ATV speedo.
It's really accurate and displays mileage, speed, average speed, temprature, max speed, time spent riding and can be set up to notify you after a certain amount of miles for maintenance.

The only downside was that the backlight didn't stay on for longer than 3 seconds but managed to combat that by opening it up and wiring the back light into the ignition with a 12v to 3v reducer.

It was the only speedo I could find that would fit inside the SV 650 speedo case without chopping a big hole in the fairing bracket.

[m40man]

Looks like you've been quite creative with this rebuild - I'd like to see more pics, especially any showing how non-stock bits have been made to fit.

Suspension & wheels changes, clocks & fairings, are always worth documenting, so others can rip off your ideas .

Pity cars seem attracted to you though - hope the buggers keep away from now on .

[detonation]

Cheers, I'm trying to make it more modern yet at the same time make it look like it could have rolled out the factory like it, I'm not after a custom looking bike.

I messed around photoshopping a few modern 'Sharp looking' fairings onto the front but they all looked too modern and didn't go with the look or shape of the XJ tank and tail as both are quite rounded and curvy and the SV fairing just seemed to fit the bill.

The FZR 600 3HE rear wheel was a straight bolt in

The CBR shock required taking the XJ bolt holes from 12mm to 10mm using special washers, I also had to cut a small piece of the undertray about the size of a 50 pence piece so I could fit the reservoir threw to hit it under the saddle.
It also required getting a longer sidestand.

The fairing frame I will upload pics of when I paint it next week,

It required cutting the top bolt hole off the SV mount then bolting the bottom bolt hole to the top XJ bolt hole then making 2 stainless brackets to bolt to the bottom XJ hole, they then bolt to the frame right behind the headlight.

The only other mounts I needed was some P clips to create a mounting point for the back bolt holes on the side fairings and had to make some infills for the small gap between the side fairings and the tank.

As I was going from 1 headlight to 2 I had to make a new headlight loom to run the headlights off the battery's using 40amp wire and a few relays.

[neilmud Lord Protector]

May 18, 2014 16:21:57 GMT detonation said:

As I was going from 1 headlight to 2 I had to make a new headlight loom to run the headlights off the battery's using 40amp wire and a few relays.

CD will be chuffed even so looking good.

Neil