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Secret Agent
2006 Honda CBR1000RR, 2008 Honda CRF230L, 2019 Honda CRF1000L
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1,394 Posts
Discussion Starter #1
Bought this bike new in 06 and used it in a number of harescramble races and it was the only bike I'd take to ORV parks like Chadwick and Milford and a couple trips to Arapaho National Park in Colorado. It's saw it's fair share of mud and water. I'd try to keep it as clean as I could, but it's got a ton of really tight spots, so over the years some grunge has built up.

Here it is in all its current glory
63549


Gonna strip it down to clean it in places I couldn't otherwise get too. Replacing the following.

Grips
Throttle tube
Bark buster plastics
All red plastics (the whites had decals keep the virtually scratch free, virtually...)
All the 'white' natural plastics
Tires, tube, rim strips
Shifter seal
Fork seals
Front and rear brake pads
Oil, filter and transmission fluid
Flush and replace antifreeze

Starting the tear down
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New Bridgestone Battlecross X30R installed on rear
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Rear subframe and shock removed exposing a decade of grunge
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Removed carburetor, I'd installed a JD jet kit when new, they ran very lean from the factory. Personally I think the extra heat from running lean attributed to the valve issues so many people had trouble with on this bike. Valves were to be adjusted ever 100 hours, seems like a lot of people stretched there valves beyond spec well before this and installed kibble whites. I had initially contemplated installing KW valves from the get go but decided against it. Mainly because they were heavier and caused a bit of power loss. My stock valves haven't moved in ~175 hours.
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This bike hadn't been started in ~3 years until this spring, gas was 3 years old. Installed new battery back in April and it fired right up. This is all the crud there was in the fuel bowl.
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Carburetor cleaned and reassembled. Lots of scrubbing on back of motor and all rubber hoses and wiring harness.
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That's enough for today. Hope to have the rear half of the bike finished up tomorrow.
 

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MODERATOR
Joined
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7,784 Posts
Excellent my Friend, story and pictures!
Sam:)
 

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Secret Agent
2006 Honda CBR1000RR, 2008 Honda CRF230L, 2019 Honda CRF1000L
Joined
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1,394 Posts
Discussion Starter #3
Little bit of cleaning and a lot of assembly. Carburetor installed, new throttle tube installed and throttle linkage adjust.

63561


Shop manual pays dividends, well worth it just for wiring and hose routing, complete with places to secure everything with factory ties.

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Removed exhaust to clean off caked on dried mud. Removed my flatland racing radiator guards and put my factory louvers back on, hard riding days are over.

63563


Should be a lot faster, flush out the original green HP antifreeze and installed the new HP2 blue antifreeze!

Drained fuel tank and pulled the strainer, wasn't too bed. Verified full/reserve settings worked while draining. With bike mostly assembled and carburetor freshly cleaned, I took the tank down and filled it before installing to see how the bike ran. Fired right up, fast idle, slow idle, throttle response like new.

63564


New natural disc and caliper 'guards'. Rear sprocket and chain are original, showing signs of wear. Contemplated replacing but I think they'll last me awhile.

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Lots of time consuming work reassembling and routing wires/hoses. Done for the day. Still got the front end to go. Job for another day.
 

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Retired twice: Navy and as a govt contractor
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13,152 Posts
Looking good
 

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Secret Agent
2006 Honda CBR1000RR, 2008 Honda CRF230L, 2019 Honda CRF1000L
Joined
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1,394 Posts
Discussion Starter #5
63655


Installed new grips and put the hand guards on. Pulled the forks to change fluid and seals.

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One fork disassembled. Gotta pick up some diesel fuel tomorrow to clean the parts prior to assembly.

63657
 

Attachments

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Secret Agent
2006 Honda CBR1000RR, 2008 Honda CRF230L, 2019 Honda CRF1000L
Joined
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1,394 Posts
Discussion Starter #6
Parts clean and ready for assembly

63680
 

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Secret Agent
2006 Honda CBR1000RR, 2008 Honda CRF230L, 2019 Honda CRF1000L
Joined
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1,394 Posts
Discussion Starter #7
63681


Damper assembled with fluid, sitting under a 15 minute pressure test. This checks to see if damper assembly leaks and/or if damper rod leaks.

63682


Outer tube and fork slider assembled.
 

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Secret Agent
2006 Honda CBR1000RR, 2008 Honda CRF230L, 2019 Honda CRF1000L
Joined
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1,394 Posts
Discussion Starter #8
63687

Beats the heck out of chasing it around on a bucket! I still spoon it on, when mounting new dirt bike tire on these rims with rim locks.

63688

I was a little disappointed to see rust inside the right fork slider tube. Fortunately, there's no sealing happening in here. Just a bushing that's on the fork damper assembly that the spring sits under. Not much surface coating worn off that bushing so I left it go. Didn't feel like spending ~250.00 for this tube. Nears as I can tell, it was probably in the metal. This fork wasn't leaking and fluid looked like new. Plus the damper rod is bare steal which extends through this tube and had zero rust.

63689

Damper assembly from right fork under leak pressure test. 20 minutes, no leakage.

63690

New front tire mounted. New front brakes.

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All back together. Oil and filter changed, transmission fluid changed. Runs like new.
 

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Secret Agent
2006 Honda CBR1000RR, 2008 Honda CRF230L, 2019 Honda CRF1000L
Joined
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1,394 Posts
Discussion Starter #9
I couldn't take the new red plastics without new white plastics...

It's done.

63739

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Loaded it up and took it home at lunch. Rode it a bout around the yard, it's got 1 mile on this service 🤭🙂
 

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American Legion Rider
Joined
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21,862 Posts
Brand new bike. (y) (y) (y)
 
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