S1000RR - The Rebirth!

After chatting to a few peeps at BB last night and mentioning the BMW, I thought I'd post up a build thread for it.

Sooo.......having converted my BMW into a Cat-B write off in Aug 2012 , I managed to buy it back from the insurance with the intention of turning it into a dedicated track bike. I'm still recovering from the accident, so I'm unable to ride yet , but it gives me something to tinker on in the garage to pass the time until I can ride again.

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I decided to forgo a replacement road bike for now and just focus on track days for a bit, with this in mind I chose to build it with a higher specification of components shown below. :

BMW S1000RR Sport
Frame alignment checked and larger taper head bearings fitted (Motoliner)
Akroprovic Evolution Full Titanium Race System
Akroprovic Carbon Fibre Exhaust Hangar
Bazzaz Z-Fi Fuel Module
K&N 2-layer 'Race' Air Filter
Ohlins FGRT202 NIX Front Forks
Ohlins TTX MK2 Rear Shock
Ohlins Steering Damper
GB Racing Engine Crash Protectors
HM Racing Quick Shifter Plus
Alpha Racing Switchgear Setup
Alpha Racing Alloy Throttle Housing
Alpha Racing Quick Action Throttle
Alpha Racing Drilled Magnetic Sump Plug
Alpha Racing Drilled Oil Filler Cap Kit
Alpha Racing Fault Eliminator Kit
Gilles ACM Titanium Lock Nut
Lightech Chain Adjusters
Alloy Clock Fairing Race Bracket/or Stock (I have both options)
BMW HP Brake Levers
BMW HP Adjustable Rearsets
BMW Tinted Screen
Brembo HPK Brake Discs
Carbon Lorraine C59 Race Brake Pads
PVM Forged Alloy Wheels
PVM Racing Brake Discs
Racetec K3 Tyres
Cap-It Sport Tyre Warmers
Renthal RR4 Chain (520 Conversion)
Renthal Ultralite Front Sprocket
Renthal Hard Anodised Rear Sprocket


The damage to the bike was (from what I can remember) :
All bodywork
Both Forks
Front Wheel
Brake Discs/Pads
Yokes/Stem
Head Bearings (lower one smashed)
Clocks
Oil Cooler
Rad (slightly bent but useable)
Exhaust System (flattened)
Clock/Fairing Support
Radiator Expansion Tank

So I'll update this thread as I go along...

So a few pictures, here is the bike after I got it home and removed most of the broken bits (the HP options etc were removed for insurance purposes).




Then I fitted some new yokes and bearings (which were changed again for the higher quality, deeper taper ones during the alignment process).





Then once they were done I fitted the new forks and the old wheel (bent) so I could take it to Motoliner, I also had to strip out all the electrics and loom from the main frame (in case it needed to be straightened). Which is why you can see the loom folded over the subframe and taped down.







Once that process was done I could rebuild the bike . I had taken about 100 pictures of the bike before I stripped out the loom, that way I could see how it laid in the frame and what went where. So I started by laying the loom in place to get a rough idea where everything should go.





And then fast forward on a couple of hours and I've reinstalled the brake pipes and all of the wiring/throttle bodies/airbox are neatly tie-wrapped back in place. I took this opportunity to fit the K&N filter also.




I've then fitted the replacement clock mounting (albeit I did buy an alloy race version, but haven't used it) and replacement clocks. I've still got to sort out the wiring at the front, but will look at that once I'm happy with the switchgear setup etc.





Then I started to fit the new switchgear (as used in racing), and on the BMW this unit takes the 'mode' switch from the right hand side and keeps all the computer controls in one place.





And a shot of how she sits at the moment, this was how I left it before Christmas so now that's out the way I'll be cracking on with fitting the rest of the components (albeit I couldn't resist fitting the GB covers).

 

Nice to see that you're up to your old tricks again Ducky. Keep us up-to-date with pics.

 

Gonna be a good thread this Chris

 

Oh I like those forks!!!!, and keep the thread going so we see how it "should" be done.

 

Is it just me, or...?

 

the garage looks a bit untidy

 

It's overdue a tidy up!

 

Glad you're up & about & up to old tricks.

 

stop messing about buy a kwacker

 

Soo I had a little spare time this afternoon and figured I'd do a bit on the bike, fitted the Q/R throttle and alloy housing from Alpha Racing and the other part of the switchgear kit.



Then fitted the AR sump plug, I noticed that the magnet on this is a LOT stronger than the stock plug, so that can only help. Needed to drain the oil anyway to replace the oil cooler so gave it an oil change at the same time.



Then I fitted the new oil cooler and mounting bracket, as mine was as bent as a plate of spaghetti! lol



Then I decided to test fit the exhaust system on the bike just to check all is ok, one thing I like about the Akro's is they fit together so nice, and the separate mounting brackets in the head makes life so easy.

 

Good to see you're not letting the injuries stop you spending money. Looking good Chris .

 

Nice!!!

 

Have boredom, will shop!

 

Soo, decided to nip back into the garage and try and power up the bike to test my 911 diagnostic unit. It's not been powered back up since it was dismantled so was interesting to see what would happen..

NOTHING was the answer! lol...so I ended up plugging in everything I'd left off which I assumed I didn't need (lambda's/servo motors). Finally got it to spring into life and was interesting checking out the fault codes (lots!!).




Still after playing around with the plugs and checking everything I got it back to no faults, except for the servo motors (still removed). I forgot to disconnect the lambdas though, so will try that next time.

Have to admit I was a bit sceptical about paying almost £300 for a 911 unit, but has turned out to be a very handy tool indeed, especially on this project build.

 

looking very good
can i send you a list for next time your bored

 

Can't you leave the Lambdas connected and simply isolate / over-ride them through the software? It'll save having to sort some plugs to fill the holes.

 

Or just shear them once a year like the rest of us. They don't do any harm, after all. I'm sure some of the ladies would help you carding and spindling the proceeds!

 

That was my original plan, but the lambda's don't fit the Akro and I can't see an option to override them in software (at least not with my 911 unit, I think you would need BMW's kit for that). However I'm hoping it will be fine once I wire up the Bazzaz unit and disconnect them it will be ok, as this is the process when fitting one.