have a bone stock 954 with 60k miles on it, and its starting to make noises and knocks. nothing terrible, but I want to completely rebuild the motor and freshen up everything.
is there a standard list of parts that need to be bought/replaced? i want to order everything ahead of time, etc. thanks
How much mileage is on the current camchain and tensioner?
How long since the valve clearances were checked?
Have you built engines before?
First, get a manual.
Then download the fiches for the engine, they show every one of the 660 pieces in the 954 engine.
2003 Honda CBR954RR OEM Crankshaft + Piston Parts | MotoSport
I don't recommend buying anything before you have the engine stripped and inspected as you don't know what is worn or damaged. If the bores are scored for example you will need to bore them and run over-size pistons and rings.
If any crank journals are worn you will need to order under-size bearings.
Essentially you will need the following parts (once you determine the exact sizes required):
gaskets and o-rings throughout (don't forget the valve guide seals)
main and rod bearing shells (18 pieces)
Not absolutely required but new rod bolts and nuts (US$75) and main bearing bolts (US$50) are cheap insurance.
Oil pump if yours is worn
Camchain tensioner (this can be done later though if yours is still okay)
Pistons if yours are worn - (don't forget to measure the ring grooves)
Piston pins if yours are worn - unlikely
Clutch springs (if required)
Clutch bearings (if required)
Clutch stake nut
The transmission will come down to replacing any worn/damaged gears, forks or bearings.
sixteen new shims will be required if you recut or lap the valves
sixteen valve guide seals
Inspect and replace any valves and/or guides, valve springs, camshafts or buckets if any are worn - unlikely though.
There is no need to replace the water pump during an engine build as it is easily done when it's required.
Not required, but I would also replace the exhaust studs and nuts with stainless.