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 Post Posted: Fri Apr 02, 2010 6:21 pm 
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If you've seen the 'Bought myself a Hornet' thread, you'll know i've got a 1999 Hornet 600 in Candy Red (Not Italian Red for some reason? Whatever i like the colour :P) and people said it looked pretty good. And yeah i guess it was pretty good, but not good enough for me. Seeing how i have 4 months until i can ride it, i've decided to completely strip the bike down and restore and improve it.

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How i bought the bike

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Tank off

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Draining Coolant

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Radiator Off

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Rear Fairing and Exhaust Off

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Destroyed Link Clip

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Poor thing had corroded to death

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A challenge

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Covered in penetrating fluid

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Failure! All but 2 snapped in the end

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After about 40 minutes of knocking and whacking the Downpipes finally came free, they were just surrounded by muck and corrosion

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The aftermath - Must get those studs out...

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How the bike is basically now

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Radiators fairly good

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The fan isn't

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Snapped the bolt taking the heatguard off the can :/

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Really mucky downpipes, they shall be polished!

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Fairly good nick other than the Manifold plates, they're completely corroded and bent from removing them

That took us about 4 hours to do, washed out the Radiator, cleaned a lot of muck off the engine.

I would make a to do list, but it would list basically everything imaginable to the bike, so you can imagine it in your head :P

Cost so far - £1650 - Bike, Abba Stand (God send, easily recommend one)

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98' 600 Project


Last edited by Digitalize on Sun Aug 05, 2012 10:49 pm, edited 4 times in total.

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 Post Posted: Fri Apr 02, 2010 8:49 pm 
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Love the candy red, looks really nice. So what have you got planned for her, just restore or getting some new goodies to swap?


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 Post Posted: Fri Apr 02, 2010 10:09 pm 
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Duce wrote:
Love the candy red, looks really nice. So what have you got planned for her, just restore or getting some new goodies to swap?


It looks better in the photos, starting to show its age, one reason i want a respray :P

New Can (Dual if possible)
New Mirrors
New Indicators
Gold Rims
Gold Renthals (Flat or Ultralow)
Gold Chinky Pazzo's
Belly Pan
Replace mudguard & Extenda
Seat Cowl
17" Front wheel if the price is right
Paint side panels Candy Red
Samco Hoses

Rest is basically make it look like new, most things getting repainted, including engine and frame, also gonna cover the raw part of the engine too.

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 Post Posted: Fri Apr 02, 2010 10:20 pm 
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:clap :clap
this is a most excellent thread ... and i will be watching the progress of your efforts :D
cant wait to see what is in the pipeline etc and the final result ... well done for now :D

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 Post Posted: Sat Apr 03, 2010 10:18 am 
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great work :thumbup :thumbup , just keep thinking of that 1st ride in 4 months . great photos and keep them coming :clap


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 Post Posted: Sat Apr 03, 2010 11:05 pm 
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Got some more work done today, pretty much stripped the front end other than forks and wheel. Got the Air filter and carbs out, didn't get the engine out but thats the goal im working towards.

Also been considering, as im gonna have a full respray, to perhaps change the colour...? Liking the Burnt Orange of the later hornets, but then i also like the red, and i wouldn't mind a purple or something. hmm....

Anyway, to the pics :P

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Drained the engine oil (Pic basically unrelated)

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Pic of where all the tubes go (Other than the ones we just took out :P)

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Other side

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Your guess is as good as mine

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Headlight rats nest

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Someone ripped all its guts out!

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How to connect the Indi's

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More pipe memory

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Air filter box off

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Looking a bit bare already

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Oh yeah, took all the left hand bar stuff off

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Carbs out

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Brakes and Mudguard off

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Not how you usually see a Hornet :P

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A different beast

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Carb holes plugged

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Plate off

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More indi connectors

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Tail tidy off

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How it was when i left

End of Day 2 - Cost Same - Problems to solve - Studs in Engine block, Manifold Plates

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 Post Posted: Sat Apr 03, 2010 11:20 pm 
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Great photo's - looks very similar to what I have been doing to mine over the last few weekends. Suspension change, carbs out for Stage 1 etc.

I had a stud break while removing my downpipes (to remove the PAIR valve) - I ended up heating the stud and then borrowing a stud extractor to s-l-o-w-l-y remove it.

A week of penetrating oil applied daily did nothing to the broken stud. 4 studs came out fairly easily (with care), 1 would not let go of the nut, so it came off with the pipes and was introduced to the angle grinder.

New studs and gaskets ordered from Dobles.

I am using an ABBA stand as well, with the Moto Glide attachment as I don't have much room in my garage and need to put the bike out of the way during the week. They are fantastic, another recommendation here.

Keep up the great work - it will all be worth it.

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 Post Posted: Sat Apr 03, 2010 11:44 pm 
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Thats what im gonna have to do, otherwise im pretty much screwed :/

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 Post Posted: Sun Apr 04, 2010 4:07 am 
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I cannot believe the amount of dirt, grime, and corrosion on a bike that is only 11 years old. :cry What is the story? At any rate, good on you for taking on the challenge of saving this bike :clap --I look forward to watching its transformation.

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 Post Posted: Sun Apr 04, 2010 10:24 am 
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bikertrash wrote:
I cannot believe the amount of dirt, grime, and corrosion on a bike that is only 11 years old. :cry What is the story? At any rate, good on you for taking on the challenge of saving this bike :clap --I look forward to watching its transformation.


Well, i didn't realise it was quite this bad, but its lived near the coast all its life, so corrosion is worse than say in the midlands.

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 Post Posted: Sun Apr 04, 2010 4:25 pm 
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Didn't get anymore work done, weather was nice so 3 of us went down to West Bay. Only saw one Hornet, stock yellow, 2000 onwards. Whole trip i kept on thinking "If i was on the Hornet, could of had him" which was annoying, seeing how im still on a 50, and one friends on a 33Bhp RS125...

Still, got this done when i got in, little piece of inspiration, if it looks like that, i'll be happy :D

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Gold Renthals
Gold Levers
Gold Wheels
Gold Calipers
Belly Pan
Gold Honda Logo's
Gold Hornet Logo's

Few other things that would be impossible on Photoshop, changing mirrors, Indi's and Can etc.

Hearing the Hornet down West Bay, surrounded by loads of other bikes, it sounded pretty crap, and far too quiet for my liking :evil

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 Post Posted: Sun Apr 04, 2010 4:28 pm 
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Painting your fork lowers gold as well would look mint someone on here did it and looked good I'll have a search.

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 Post Posted: Sun Apr 04, 2010 4:32 pm 
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#46 wrote:
Painting your fork lowers gold as well would look mint someone on here did it and looked good I'll have a search.


Im not sure if it would be 'Too' gold then. I really wanted the Tubes gold, but screw £200 for it :|

Any pics of Hornets similar would be great, but of course, im taking a jump of faith hoping it will come out nice :P

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 Post Posted: Sun Apr 04, 2010 4:33 pm 
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http://www.hondahornet.co.uk/messageboard2/viewtopic.php?t=14817&highlight=hammerite+smooth

Look at the post by spaglemon :D

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 Post Posted: Sun Apr 04, 2010 4:38 pm 
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Not sure tbh, i did a mockup and it was just too much.

But then, the gold i actually want is a little darker than the mock up, just photoshop quickly goes mucky gold, its hard to describe, kinda like the R1's Gold wheels.

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 Post Posted: Mon Apr 05, 2010 3:07 pm 
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Wannaprilia
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good lad for getting stuck in there!!
made me larf with the "not how you normaly see a hornet"

you should come to my house at the mo.lol

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I've always thought supermarket shopping trollies should come with renthals, soo much more comfy, plus its something to keep you busy whilst being dragged around by the missus.


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 Post Posted: Mon Apr 05, 2010 5:38 pm 
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Got back out there today, determined to get the engine out...

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To jog my memory

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Ignition coil connectors

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Spark Plug connectors out

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Lovely sprocket cover... :eek

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Brake side off

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Sprocket and gear side off

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This happened... after a lot of shouting...

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There she is

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Some of the parts, and my dads covered up kit car (Cobra)

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To be polished...?

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What a lovely pair of calipers

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Into the workstation

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Must. Sort. This.

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Spun Bolt... Get the drill :evil

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All gone

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Need to sort that too...

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How the 'bike' is now

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How i left the engine

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Oh yeah, couldn't get the actual tail light out, ideas?

That's it for today, i've past the point of no return now, no coming out until she's on the road. :D

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 Post Posted: Mon Apr 05, 2010 5:47 pm 
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nice work.

if i remember correctly, there are 2 square shaped nut thingies underneath the tail light holding it in place? cant remember if that was the light unit or undertray too...

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 Post Posted: Mon Apr 05, 2010 6:23 pm 
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Fantastic going mate, great bit of Farther, Son bonding going on. :Beer


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 Post Posted: Mon Apr 05, 2010 9:45 pm 
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Whoa! Looking the first pic I thought "Hmm... That's a good looking bike. Nice and clean..." But seeing how much there was dirt and muck. Eeew!

Kinda makes me wonder. Should I remove my tank and covers and stuff and see how things really are underneath all the fancy polished surface...

Removing the tail light can be tricky. There's two bolts, and the "nuts" are glued inside the plastic. If the glue breaks the (probably round) nuts start to turn with the bolts. And then my friend, you have a shitty situation.


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 Post Posted: Tue Apr 06, 2010 11:07 am 
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If the 2 bolts are behind the light, pointing to the back of the bike, then yes, i do have a shitty situation :/

To be fair, i still think it looks worse than it is, just needs some lovin, and time.

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 Post Posted: Tue Apr 06, 2010 1:10 pm 
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Digitalize wrote:
If the 2 bolts are behind the light, pointing to the back of the bike, then yes, i do have a shitty situation :/


Yep those are the ones I mean.


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 Post Posted: Wed Apr 07, 2010 2:00 pm 
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Dropped the engine off with a guy I know who has his own engineering place. Hopefully he can get the studs out with a bit of luck. Think I'm just gonna have to replace the downpipes, the manifold plates are basically all rust now, wouldn't want to trust them holding the pipes on. He also mentioned removing the baffles from the downpipes to give it a bit more noise... :evil

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 Post Posted: Wed Apr 07, 2010 2:37 pm 
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as far as i know, they dont have baffle in the headers dude?? you sure about this??

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I've always thought supermarket shopping trollies should come with renthals, soo much more comfy, plus its something to keep you busy whilst being dragged around by the missus.


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 Post Posted: Wed Apr 07, 2010 2:41 pm 
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Digitalize wrote:
Dropped the engine off with a guy I know who has his own engineering place. Hopefully he can get the studs out with a bit of luck. Think I'm just gonna have to replace the downpipes, the manifold plates are basically all rust now, wouldn't want to trust them holding the pipes on. He also mentioned removing the baffles from the downpipes to give it a bit more noise... :evil


Blatently recover the manifold! Bit of elbow grease, wire wall / wire brush and autosol! It's Stainless as stanndard - though not sure about the plates. I'm messing with mine now on my '00 plate to see if i can bring them bacck to life! :)


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 Post Posted: Wed Apr 07, 2010 3:54 pm 
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naxj wrote:
Blatently recover the manifold! Bit of elbow grease, wire wall / wire brush and autosol! It's Stainless as stanndard - though not sure about the plates. I'm messing with mine now on my '00 plate to see if i can bring them bacck to life! :)


the actual pipes I could save easily, it's the plates, they're just completely corroded.

Guy said he used to take baffles out of a lot of downpipes, cut them open, remove and re-weld.

Got out a bit again, stripped it down to just the rolling frame now, only 1 quick iPhone pic for ya

Image

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 Post Posted: Wed Apr 07, 2010 4:53 pm 
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That's one over-engineered push bike you have there. :eek :D

My pipes need a bit of TLC - but the plates are nowhere near as corroded as yours. If you know a good fabricator they may be able to cut those off, make up a new set in 2 halves and then re-weld them "shut" once they are on the pipes.

Luckily mine are going to get treated with Kurust, then painted with some High Temp paint (like this)

Keep up the great work. :clap

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 Post Posted: Wed Apr 07, 2010 5:21 pm 
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the pipes are stainles, but not the plates.doh!!

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 Post Posted: Wed Apr 07, 2010 5:30 pm 
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Picked the engine back up from my guy, he got them all out, £30 in his pocket for beers, job done. Also knows a guy who will do blasting and powdercoating on the side, he paid him £150 for wheels, frame and a few bits, which seems pretty good, just waiting to see if he can get us in contact.

Another quick iPhone pic, loving the photobucket app!

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 Post Posted: Wed Apr 07, 2010 5:52 pm 
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Horness wrote:
High Temp paint


Problem with Hightemp paint is it needs to get hot to cure, and only way to do that other than bake it is to ride it, which means the paint finish will get ruined...

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 Post Posted: Wed Apr 07, 2010 7:59 pm 
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Digitalize wrote:
Problem with Hightemp paint is it needs to get hot to cure, and only way to do that other than bake it is to ride it, which means the paint finish will get ruined...

Once painted and fitted I will be balancing the carbs etc. - so the bike will be running and getting to temp while sat in the garage.

It's more for protection than for cosmetics.

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 Post Posted: Wed Apr 07, 2010 8:18 pm 
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dudeskin wrote:
as far as i know, they dont have baffle in the headers dude?? you sure about this??


the only bit of the headers that has a "baffle" in is the thicker two bits just before the pipes go into one to go up to the can!
they contain two perforated tubes (one in each buldge), but dont know what they do!


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 Post Posted: Wed Apr 07, 2010 8:33 pm 
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Im guessing the baffles just make it quieter, still, i may do it, all for a little added noise :evil

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 Post Posted: Wed Apr 07, 2010 10:12 pm 
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Oh forgot to mention, my frame claims its a CB600FW, not the FX it should be for a 99 bike, so it seems its an original 98 bike, that was registered in 99.

No real problem as there was no difference, just interesting to know.

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 Post Posted: Wed Apr 07, 2010 10:31 pm 
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My old Fazer had the headers 'smoothed' out, was meant to make it go faster!! :blahblah


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 Post Posted: Wed Apr 07, 2010 10:43 pm 
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Not really worried about speed as its restricted anyway, so its gonna do about a ton. Just sound :P

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 Post Posted: Wed Apr 07, 2010 11:33 pm 
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Digitalize wrote:
Not really worried about speed as its restricted anyway, so its gonna do about a ton. Just sound :P


but you wont hear it :angel as at a ton you need to be more aware of wots going on in front than the screeeeem behind cue the :copper

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 Post Posted: Wed Apr 07, 2010 11:37 pm 
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APECAR wrote:
Digitalize wrote:
Not really worried about speed as its restricted anyway, so its gonna do about a ton. Just sound :P


but you wont hear it :angel as at a ton you need to be more aware of wots going on in front than the screeeeem behind cue the :copper


It will all be on those special private airfields we all have of course.... ;)

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 Post Posted: Thu Apr 08, 2010 1:10 am 
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do more than a tonne at 33bhp :angel


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 Post Posted: Thu Apr 08, 2010 2:08 am 
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Welshd1k wrote:
do more than a tonne at 33bhp :angel


Not much, anything 33 will do ABOUT 100mph, give or take about 5mph. I can't see it going much faster than 105 tbh.

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