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Discussion Starter #1
Hey fellas, here is my build thread for my wr3ck as i call it.
I purchased a 954rr of of offer up for cheap , I guess the prvious owner thought it could not be fixed.
The engine case cover is shattered on the left side and was held together by what looked like fiberglass resin.
The bike would fire up but stall and barely rev.
The HTEV is malfuctioning, and clicks the entire time the key is on.
In my neck of the woods, anything is fixable. Bad frame/ replace it/ bad engine/ rebuild it/leaky forks/new seals...etc.

the bike has 22k and sounded good and the clutch worked.
the frame is straight and clean
the wheels and tires are fine
the electrical system and harness seem to be in order.
The gauges and fairing stay are on.

IN this thread, I will try to bring this bike back from the dead.
I will begin by jbwelding the case together temporarily until i get it tuned and then weld the pieces back on.
I think my favorite bike of all time is the 954. Ive had some good times on one back in the day.
Ive been messing with some gsxrs and kawis lately but nothing runs like a honda.
Today, I reassembled the engine case cover by placing the pieces carefully and setting them with gorrila glue gel.
after that dried a used the 2 part jbweld to hold them there and give stability, then i went over that with jbweld stick for some structural strength.
Now i have a drop every 10 seconds, from an area where the cases dont meet flush, but I may be able to make that stop by some minor filing of the case.
then to be welded after tune up
anyway, I will post pics as I go and begin to bring this ancient beast back to a commuter/stuntpiece.
I have ordered the KENSMO fuel pump which i have had some good results with and upon its arrival iwill begin to sort out my fuel issue
Then I will try to stop the small oil leak
then I will begin to compile the parts i need to bring it back to a full fairing stuntpiece for daily commute and stoppie practice.
cliffs; I bought a pos and now i will begin to being it back to rideable condition posting pics along the
way.
first few pics.
 

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Hiya Mace. I love these threads. I recently 'resuscitated' a little aprilia RS50 so understand first-hand the works and problems you will face. But a great flush of accomplishment awaits!!

It's always an advantage to have the essence of a good bike to begin with. I am new to ownership of the early (although 929's not truly early) Blades, but from what I see on eBay, you'd probably have no difficulty with parts.

I love those high mount exhausts; always have. Look particularly good on VTRs and aprilia RSVs, never seen one on a CBR before.

Will you leave it 'Ninja' green?:grin

I'll follow with interest. Cheers!!
 

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Discussion Starter #3
@nigelrb .....whats up bro.
yes i am kind of addicted to bringing neglected bikes back to life, there is something vastly rewarding about it, you know, when you finally get it dialed and your hands are all cut up and the amount of grease under your fingernails cant be removed. you wipe your hands off, cross your fingers, press the start button and if it fires and revs, you look up to the bike Gods and smile.
good times.
That high mount sounds great and looks cool I agree. Likely i will keep the rims powdercoated green and go with all white bodywork with headlight delete on the front fairing where i fill in the headlight hole and put in a angel/demon eye projector for a racing look, I am on hold waiting for the kensmo pump, so In the meantime I will begin the hunt for some parts..............
I had black one and a black and red 954....ive had more than a few bikes but the 900 929 954 is probably among my most favorite bikes of all time
thanks for checking it out i usually post up huge pics through photobucket but refuse to pay them for this so we will have to view the thread with attachments.
cheers bro
 

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Discussion Starter #6
Nice work!
Well this "wreck"
now runs perfect.
The tip over sensor was hanging at an odd angle
The plugs were fried
The fuel pump was all clogged up and the inline fuel pump filter was unable to pass fuel through.
I changed the plugs to some fresh NKG CR9E.
i removed the fuel pump and ran it in a glass jar to clear out all the old debris. Ireplaced the "sock filter and cleaned the whole pump with carb cleaner. Then i chucked the inline fuel filter and just ran a straight line temporarily with out the second filter for testing purposes.
I also replaced all the rubber fuel lines and bench tested the pump before install.
Put it back together and man it sounds good. I have a vid ill post later.
Now on to trying to stop that slow leak, and acquiring some plastics and rear seat and other assorted goodies like bar grips and some minor stuff.
Ill place that new pump in anyway when it arrives but for now, cleaning this one did the trick.
The only problem is the gasket on thebottom of the tank where the fuel pump goes is leaking like a seive.
and tips on that would be appreciated!
wr3cks for the win!
 

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Discussion Starter #7 (Edited)
1st day after questionable inibriated purchase.
runs good.
now lets make it worth looking at and ride the sh!t out of it
how do you change your avatar on here?
do i need like an it guy to help me do this
tomorrow i will repolish the frame as I wait for a **** ton of parts in the mail
 

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Always gratifying to get a dead bike running! Sounds as if you have no probs with mechanical issues. Not sure I'd have the confidence to tackle such things now - despite having been a Honda mechanic in the 70s.

For avatar, click on 'User CP' at top right of screen and then 3rd box down on the left you'll see 'Settings' and 'Edit Avatar' is in that box. You will have to shrink whatever pic you choose to 150 x 150 pixels.:wink
 

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Discussion Starter #9 (Edited)
Once a mechanic, always a mechanic bro nice to hear from you again.:wink
As a former stuntrider I was forced to learn how to fix my own bike, along the way I was forced to fix other peoples bikes and cars and trucks and boats.
After about a million hours logged into youtube learning from top mechanics I consider myself a "technician" halfway between a helper and a lead guy.
For a living, I actually work on Harley-Davidson, putting all the bad boys motos back on the road.
Last night, i took off the stator cover again and filed down the area in question and used what is now my favorite product;
Permatex RIGHT STUFF. Its not like normal gooey crappy permatex, It creates a seal in minutes that becomes like hard rubber. Ive used it on mnay things lately, with surprising results.
Its a little pricey, however it is worth it, I also used it to create a double seal to the fuel pump that I let sit overnight.
no leaks yet from the jbweld job, I can live with a drop or 2 anyway for now, if it leaks again I will try to nickel rod the area as I have never done this, but have been doing research and it looks like a great way to handle cracks/ breaks like the ones on this engine case.
cheers brah
more dumb pics
On a side note it wont lwt me remove the button for "do not use avatar" I think mine is stuck like that maybe a mod can unlock it?
as you can tell my IT skills are not as good as my carb rebuilding.
 

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Discussion Starter #10 (Edited)
So here is what I got so far fellas.
Craefully jbewelded the engine case back together. ! drip about every 5 min when sitting.
Full fuel system overhaul
attach front calipers and bleed/flush lines
repolish frame
change plugs to NGK CR9E
change oil
used right stuff gasket maker to mount fuel pump/ no leaks
Test ride/ flawless
mounted angel/demon eye to get me by until my cheapo ebay fairings arrive
some other maintenance and tightening of all bolts
On the list;\
New race fairings
grips
tank fuel tank cover/ quick release
ride the ever living fuKc out of it.
not bad for a days work.
 

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@mace The only way to get an Avatar is to become a "supporting member". I used to pay the $15 a year, then decided to just drop $40 and become a lifetime member. Been here since 2013 so im saving money now lol

Sweet project. I had to repair the case on my 99 900. Permatex Ultra Black with some filing and a gasket did the trick to stop the leak.












Great job on your rebuild :thumb:
 

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Discussion Starter #12
Thanks Ian!
that is a quality job there. It looks welded I need to weld mine after a while, the jbweld is suitable for now, But I dont have faith it will last forever.
Pulling the trigger on some race fiberglass tonight.
Hope to get it looking better and then go back and weld the case so its fixed proper.
Thanks for dropping by bro
I was wondering why I couldnt change my avi
nuff said
cheers!
 

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@mace The only way to get an Avatar is to become a "supporting member". I used to pay the $15 a year, then decided to just drop $40 and become a lifetime member. . .
The 'Lifetime' membership is logical.

I'm a bit cautious; thought I'd check you guys out first!!:smile

Oh yeah, and 'lifetime' for me is on a dwindling scale. Why is there not a pensioner rate!:grin:wink
 

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Discussion Starter #14
The "mock up"
the fairing are not fitting like i wished they would, I will have to modify them before I paint, drill all the holes and place the fairing bolt kit.
errrg.
 

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The "mock up"
the fairing are not fitting like i wished they would, I will have to modify them before I paint . . .
Looks as if it wont need much adjusting though. Will look great once painted.


I have some great OEM fairings i could send your way very cheep lemmy know..
Gee, if that doesn't bring on a membership rush I go and buy a Suzuki!!:devil
 

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Discussion Starter #17
@K900cbrr Thank you for the gracious offer. I have in mind a non stock looking bike however with all fiberglass race fairings and a endurance style headlight.
Then I will likely throw some bellypan decals and a logo on the tank.
It will be all gloss black with the green rims and white decals.
I now have my new quick release gas cap on there as well, which is good because I was riding without a cap at all.
Im still riding without any grips and my fork seals are leaking real bad, so Ill have to pull the forks and do that job as well.
The existing fuel pump blew the line off in the tank so I had to repull it and reattach the line with a better hoseclamp, the new KEMSO fuel pump arrived, however I will save it until the existing one shows signs of not being able to push
If my windscreen arrives I may have it all painted drilled and assembled by Sunday, If anyone out there has a stunt cage, let me know I dont care if its ratty or not.
My other option is to brush up on my welding and make one of my own design, I am leaning toward that option as the cages these days are like 450 bucks, I can make one for about 100
Thanks for checking it out Nigel, I hope after its all said and done I will have a replica of the one I had back in the day.
Ive been riding Kawasaki, and I like Kawasaki, however I had a zx10r 06, and it had a bunch of cracks in the frame.......nice looking and nice running bike, but the welds over there at Kawasaki are the worst example of craftmanship I have ever seen in my life, Ill propably never own a later model Kawi again after viewing that horrible work .
shame on Kawasaki for letting a 200 mph bike leave the factory with a frame like that
smh
Till next time
 

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. . . I like Kawasaki, however I had a zx10r 06, and it had a bunch of cracks in the frame.......nice looking and nice running bike, but the welds over there at Kawasaki are the worst example of craftmanship I have ever seen in my life . . .
Huh? And parent company Kawasaki Heavy Industries builds ships?

Have the Titanic historians looked into this?:eek::wink
 

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@K900cbrr Thank you for the gracious offer. I have in mind a non stock looking bike however with all fiberglass race fairings and a endurance style headlight.
Then I will likely throw some bellypan decals and a logo on the tank.
It will be all gloss black with the green rims
Holy moly, sounds ghastly. More like a ZX7R
 
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