KoleDeRacer Restoration and Mod Thread. - Honda RC51 Forum : RC51 Motorcycle Forums
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post #1 of 86 (permalink) Old 02-08-2016, 11:05 AM Thread Starter
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KoleDeRacer Restoration and Mod Thread.

Well i bought my second RC51 a couple weeks ago. It was a mess but i got an amazing deal on it going in. So i decided to start a new thread documenting the progress, modification, and suggestions to hopefully help the next person that decides to do something illogical like restore an early 2000s sport bike.
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2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500
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post #2 of 86 (permalink) Old 02-08-2016, 11:07 AM Thread Starter
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When i first bought the bike the color scheme on it was essentially a mix between all SP2 red/silver/black bikes.

It has a 2004 tank
2002 side fairing and nose fairing
2004 tail

Here are the pictures when i brought it home




2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500

Last edited by KoleDeRacer; 02-11-2016 at 12:03 PM.
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post #3 of 86 (permalink) Old 02-08-2016, 11:20 AM Thread Starter
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Well lets start with the bad. I new about many of these when i bought it and many i did not. But that was to be expected since also cost less then a full akro...

-Clutch cover is cracked.
-Right side fairing has rash but it reparable.
-Right said radiator is bad.
-All of the bike has general rash
-Jardine slip ons have rash.
-Bar ends are missing
-Tires are dry rotted
-Chain is trash (has returned to almost a solid piece of metal)
-Snorkel has a hole in it
-Engine is just fitly (was in a barn for 5 years)
-One mirror is "carbon" one is black.
-Most over the plastic on the handle bar switches is bleached.

So that is the bad.
The good.
-Its and RC51
-It supposedly has 12k miles (i have my doubts more on that later)
-For its condition the motor felt perfect. Every shift was perfect. It started right up with no real smoke.
-Are the plastics except the front fender are repairable
-Has a Corbin seat!
-Has read seat and solo cover
-It was cheap
-I like to work on things and restore them
-Its and Rc51

2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500

Last edited by KoleDeRacer; 08-11-2016 at 05:04 PM.
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post #4 of 86 (permalink) Old 02-08-2016, 11:21 AM Thread Starter
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Reserved for plan of Action

So because the bike was in such..... Poor shape, I decided it would probably be best to do a ground up restoration starting with the frame.

I am sorry i do not have more pictures of the disassemble but i was in the zone.

I will post some of the engine as i have not cleaned it yet other than the valve covers. I will also take more pictures of the plastics as i have not really started on that either yet and
they are all laying in the spare bed room.

But in the mean time, I decided to powder coat the frame and swing arm instead of paint it. I did this for a number of reasons.
-Its cheaper
-The color was almost exactly the same. It would be hard to tell unless it was side by side.
-It is way more durable
-It is easier to was.

I also decided i would powder coat the wheels why i was at it. I decided to go with a cast bronze/brass color much like a lot of the factory magnesium wheels. (i know this is not original color. But i like it.).

Both of these items are currently at the powder coaters.

The next step will be to clean the engine. I have not decided how exactly i will do this one as the oxidation is pretty bad in some areas.
I do not really feel like splitting the case right now either because with everything else i don't have the budget right now for what i want to do inside so it can wait till next winter.
I am going try the purple chain de-greaser first and see where that gets me. After that i will probably go to surface prep scotch bright pad and see how that goes. If that does not work last resort will be soda blast. But i would rather not do that to this engine right now as some soda always finds its way it. For the stator cover i will just remove it and polish it back.

While i was cleaning the valve covers and had them off i decided to check the valves clearance. This is why i mentioned earlier the bike may have more miles on in the what the dash says. Maybe someone can tell me what they thing as i know if also depends how hard its been ridden. Currently the bike has about 12,500 miles on the dash. The valve clearance for the intakes were .14mm for two of the valves a very tight .14mm for one and the other was .13mm The exhaust were at .28mm for 2 of them and .30mm for one and .31mm for one. While i know these are "in spec) they are at the bottom of the adjustment. It looks like everything is still factory on them so i don't think they have been changed before. But what do you guys think?


After the engine is clean the plan of course is new bearings for the wheels and swing arm and linkage (figured might as well do them all now)
Then begin to put the bike back together only using bolts that look good. If they do not i will get new ones.

I will also rebuild the front forks and replace seals and wipers.

New tires of course also.

Once the core frame is together its time to start modifications

i have a 520 chain conversion coming from kyle racing
Kyle raing pair covers and a PCV coming from kyle racing
I also bought a different exhaust and am in the process of restoring that.
I have also bought a new (used) battery tray since mine is 90% missing.

I will also be doing a breather and catch can mod.

Along the way i will be cleaning or restoring any parts that need it and getting ride of any unneeded parts.

Once the core bike minus fairing is finished the fairing restoration will begin.

I am going to remove all the graphics from the whole bike to start with.

Then both side farings especially the right will be restored filled and sanded etc and resprayed in factory red.
The front fairing is in really pretty good shape so i have not decided here yet really but i may just go ahead and have it resprayed in silver so everything is new.
Finally i will respray the tail and under tail black like it is supposed to be after some mild sanding and filling.

For graphics i found a guy that has been doing exact factory replicas for 2000-2002 bikes. I ended up ordering these with the with both black tail stickers and silver tail stickers since they are the same shape other than color. Once i got these in and saw how well he really did. They are spot on. I started thinking about the bike more i decided i wanted to do true 2003 graphics so if anyone needs a set of 2000-2002 graphics i have a full set. The only problem was no one has 2003 graphics anymore and Honda only has one side. Luckily i talked to the graphics guy and he is going to be able to make the full set from one side by computer magic or whatever so i got those from Honda for the one side and sent it to him to be made. Some i had him not cut and holes in the left side since that is the one we made from the mirror of the right so there would not be any problem there and i can just cut them.
The only thing i do not have is a template of the front graphic for the 2003 so if someone was willing to send me a picture of possible draw out a template that would be awesome.

That leaves the only problem being the tank since it is a 2004 and does not have the gold/yellow lined Honda and wings since my tank has one small dent in it where the bar probably hit i think i will have it repaired probably just spot painted then re-cleared. And since i am doing that i could add the boarder around the Honda. Also if someone has a few up close 2003 tank pictures they could post that would be awesome.

Also these graphics will be available for sale when we finish and test them on my bike.

Also i will either send my radiator to Myler's radiator to be repaired, buy a good used one from someone, try to buy one..... Someone please email me if they have one even if its a little messed up some yahoo jb welded a bolt into a whole in mine....

So this will pretty much put the bike back the way it is supposed to be.

2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500

Last edited by KoleDeRacer; 02-08-2016 at 12:59 PM.
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post #5 of 86 (permalink) Old 02-08-2016, 11:22 AM Thread Starter
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Reserved for new parts i have bought so far

Wibbly SPAL fan mounts

New Honda sp2 fairing stay

I am a 2-1 fan so i bought a Jardine 2-1. I was used and somewhat beat up but i wanted the stainless so i could well on it if needed easy enough for the auto tune bungs.Also there is only one small dent which you can see but that will be fixed.
I have already cleaned up the front header.
Someone did a horrible job cutting that can down and cut the core too short so if anyone happens to have a 57mm core please let me know.
I plan to replace the can with a 60mm core lady bird moto gp can.



I also have bought the radiator fins from Moriwaki because i like them and some cool red and blue tsr shifter nuts . Thanks simon.



Big thanks to Kyle racing for the help. From them i bought
Pair block off, Chain and sprocket, PCV





For tires i ended up going with the AVON 3D. They have always worked well for me.


The rest of the parts so far with the exception of the new graphics have been honda parts.
-COVER, CLUTCH for — s 11350-MCF-D60
-GASKET, CLUTCH COVER for — s 11356-MCF-000
-BOOT, SLEEVE for — s 43132-KT7-761
-BOOT B for REAR BRAKE CALIPER— Honda RVT1000R-03-JPN-A
-BOLT, SOCKET (8X30) for FRONT BRAKE CALIPER =
-BOLT, TORX (8X40) for FRONT BRAKE CALIPER
-BOLT, TORX (8X35) for FRONT BRAKE CALIPER
-PIN, HANGER for FRONT BRAKE CALIPER
-O-RING (51X2) for REAR WHEEL ('02-'05)
-BEARING, RADIAL BALL (6005) for REAR WHEEL ('02-'05)
-DUST SEAL (35X52X7.5) for REAR WHEEL ('02-'05)
-BEARING, RADIAL BALL (6205X2) for REAR WHEEL ('02-'05)
-BOLT, SWINGARM PIVOT for SWINGARM ('02-'05)
-WASHER (18X32X2) for SWINGARM ('02-'05)
-NUT, U (18MM) for SWINGARM ('02-'05)
-DUST SEAL (28X37X4) for SWINGARM ('02-'05)
-BEARING, NEEDLE for SWINGARM ('02-'05)
-DUST SEAL (27X34X4) for SWINGARM ('02-'05)
-BEARING, RADIAL BALL (20X37X9) for SWINGARM ('02-'05)
-CIRCLIP (INNER) (37MM) for SWINGARM ('02-'05)
-DUST SEAL (26X37X5) for SWINGARM ('02-'05)
-LABEL, HIGH ALTITUDE | (Optional). for CAUTION LABEL ('02-'05)
-LABEL, DRIVE CHAIN for CAUTION LABEL ('02-'05)
-LABEL, CHAIN ADJUSTER for CAUTION LABEL ('02-'05)
-LABEL, TIRE for CAUTION LABEL ('02-'05)
-COVER, BATTERY TRAY for REAR FENDER ('02-'05)
-BAND, U-LOCK for REAR FENDER ('02-'05)
-RUBBER, METER CUSHION for SPEEDOMETER ('00-'03)
-SCREW, TAPPING (5X16) (PO) for SPEEDOMETER ('00-'03)
-WASHER, PLAIN (5MM) for SPEEDOMETER ('00-'03)
-All Balls bearing and seal kit RVT1000R RC51 2000-06
-New for seals and wipers


Well thats all for now. I am sure i am for getting something

2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500

Last edited by KoleDeRacer; 02-11-2016 at 12:05 PM.
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post #6 of 86 (permalink) Old 02-08-2016, 11:23 AM Thread Starter
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Future mods later this year will be

DHC open air box
DHC snorkel
DHC rc211 front fender
DHC rear huger
power commander auto tuner
Power commander quick shift
Lady bird titanium moto gp cab

Later later this year
HO204 Ohlins
Either Kyle raing rework or 30mm NIX kit


Mods next winter will be

Revolution racing cams and head work
JE piston 11:1
Carrillo rods
falcon balanced crank to rods and pistons
yoyo slipper

At some point along the way
Brembo or cbr radial masters
Better rearsets
Better clip ons
Brake tech rotors
Braided lines

2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500

Last edited by KoleDeRacer; 02-08-2016 at 12:59 PM.
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post #7 of 86 (permalink) Old 02-08-2016, 11:23 AM Thread Starter
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Reserved for i am not sure but might need it/future problems

Well i hit a little hiccup last night...
I went off and bought a pair of these for lunch money.. I just could not pass it up.





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2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500

Last edited by KoleDeRacer; 02-08-2016 at 11:34 AM.
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post #8 of 86 (permalink) Old 02-08-2016, 11:24 AM Thread Starter
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Reserved for rebuild.

Well here are some more pictures.
The frame has been sandblasted and is ready for powder.



Wheels are ready for powder also



Swing arm would have been except at some point apparently some kind person ran it without a chain slider?? so it is being welded and repaired right there where the split is.




2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500

Last edited by KoleDeRacer; 02-11-2016 at 12:13 PM.
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post #9 of 86 (permalink) Old 02-08-2016, 11:24 AM Thread Starter
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Reserved for Rebuild progress

I also started the process of cleaning the engine up.





As you can see the thing is nasty

I decided to go ahead and pull the heads to see how everything looks. There is one scratch at the very bottom of the rear bore that is where the ring gap is that is a little concerning. But it did not smoke at all before so its probably fine for this summer till i do a re-plate and JE pistons next winter.


Last edited by KoleDeRacer; 02-11-2016 at 12:22 PM.
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post #10 of 86 (permalink) Old 02-11-2016, 12:23 PM Thread Starter
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Went ahead and cleaned up the head while it was off.






Now i have that honda twin back together and clean.

2003 RC
1988 FZR1000R
2013 YZ-450f
1974 Yamaha RD350
1971 Honda CB500
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