Shug Tech » Bikes

1999 Honda Hornet 600cc Rebuild

shuggyboy — Mon, 01 Mar 2010 14:06:02 +0000

I bought a “basket case” 1999 Honda Hornet 600 model, The engine was blown according to the last owner.

Check out the Updated Pictures

Update 2
Update 3
Update 4
Update 5

I stripped the head off and found 6 of the inlet valves were seized open, I found a 2nd hand cylinder hear on eBay for £50!! so I’m just waiting on the head gasket, that was another £50! The cylinder head just arrived tonight so im going to strip it to make sure it is ok.

hopefully rebuild it possibly using some of the shims from the old head to set the clearances, I have already cleaned the pistons and they look to be in pretty good shape, anyway, here are some pics, I hope to keep you updated as i go along, im planning to powder coat the wheels ans possibly the frame etc, I was thinking of gold wheels and blue tank etc, but im wouldn’t mind some suggestions for colour choices!

Update 2

that’s the wheels, footpeg brackets all the odds & sods away for powder coating,

I have refitted the engine to try it, and it sounds good, i have painted a few bits and tidied up others, its getting there, heres some pics of the bike now.

Update 3

I just received a load of parts from the powder coater toady, they look the biz, check it out, the colour is titanium metallic, with a clear coat of lacquer with sparkle through it….

Update 4

got a bit done today,,, should be ready to fire up tomorrow…

Update 5

Well, I tried what you were saying and used some 800 then some 1200 wet and dry to clean up the pipes then polished with some auto sol, its just about finished, just a few wee snagging jobs left, like fitting a new speedo cable, I had a quick shot today and it felt superb,,, going like the clappers….. only problem is though that the oil light is coming on when the engine is idling!!!! im going to have to have a look at the oil pump i think?
anyway here are some more pics….

Hope you like it… feel free to leave your thoughts?

Another Honda CR 80 Re-build Part 1

Marty — Mon, 10 Aug 2009 15:53:28 +0000

Well Shug got his hands on another Honda CR 80 bike, the frame is already away to get powder coated,

Included with the bike was a few boxes containing no less than 2 engines, which were all completely stripped down to nothing,this gave shug a chance to start his magic, working on each side casing for the bike, he started off by de-greasing all the parts using a small toothbrush to get into the nooks and crannies,

box of bits

After a few hours, lots of de-greaser, some spray paint, the engine started to take shape,

Nice Spray Job

after the paint had dried a little it was time to swap out those standard looking bolts, and replace them with the nice new purple anodized bolts

nice new Bolts

close up of the small dent in the side casing…

new bolts

1998 Kawasaki KX 250

Marty — Mon, 10 Aug 2009 15:40:19 +0000

Another Bike hits the shed with shug going all out to build this monster from the ground up,

including new power coated frame, take a look through the pictures below, as always feel free to leave your feedback.

Something Else to Read?

1997 Honda CR80 Re-Build Part 3 Completed

Marty — Wed, 22 Apr 2009 20:53:22 +0000

If you havent already done so.. check out part 1 & part 2 of this 1997 honda cr 80 complete bike re-build

looking back over the previous posts, looking at the pictures its hard to believe this was the same bike which was loaded into lots of buckets and left to waste.. but once again shugtech worked his magic and restored this brilliant crazy bike back to its former glory…

This project took just over a month to complete, including getting the engine building it up and restoring the frame, adding the plastics, getting the seat all re-covered and wired up. I have to say the decal kit looks amazing, agasint the white frame, the cr 85 exhaust bolted on the back just sets it off and gives it just a brilliant ring to it when its started up.

Enjoy the pictures feedback welcome

~~Check My Ebay if anyone is interested in buying this bike….~~

The bike is now SOLD, thanks for all the interest.

1997 Honda CR80 Re-Build Part 2

Marty — Thu, 02 Apr 2009 22:12:06 +0000

Well after a few weeks of intense labor and great team work (well done shug) the CR80 is (nearly)re-born..

A few weeks ago when a box of bits which resembled a cr80 (part1) was dropped of to the shed, in what I thought was going to be a struggle to get it looking, the way it should be after seeing the crap that was in some of the boxes, but shug worked his magic once more and has re-built this bike and restored it back to it former glory, well except this small list of bits which are still in need of attention

Seat cover(didn’t have the staple gun for this post),

front caliper

exhaust can mount (paddy did a great job of the other front section brackets)

Once these parts are looked at and finished the bike will be ready for sale…also a better look at it in more detail in a future post…

Have a look at some of the pictures below…
feel free to leave your comments…

1997 Honda CR80 Re-Build Part 1

shuggyboy — Sun, 08 Mar 2009 16:02:27 +0000

Documenting the process taken to rebuild a Honda CR 80.

I rebuilt a different CR80 engine for a guy and told him i’d like to install the engine into the frame myself so no one would wreck it, after all the engine was loaded in and tested i doubled checked the whole bike for anything and returned to its owner the guy was very pleased so he gave me his other CR80 which was all in various boxes and in need of some shugtech time.

Over the coming weeks I will document the steps I’ve taken in order to restore this bike back to its former glory.

below are a few images of step 1, I layed all the possible parts i found from all the boxes and made a list of all the other parts i needed, the engine for the bike wasnt there so a quick 5 mins on ebay found me a nice little donner for this bike, a cr80 engine with a few bits missing.

2002 MotorHispania 50cc

Marty — Tue, 06 Jan 2009 00:17:44 +0000

The 2002 MotorHispania 50cc bike was picked up from somewhere near Carlisle, the bike like most, was all in boxes scattered across a workshop and back garden, so after about an hour or so collecting and sorting the parts, it was all moved to the back of the van ready for transport home…

During the restoration process ill update this page with new images and progress on how each section of the bike is coming along.

What i would like to do is start adding some videos of the basic technique’s I use through-out this project and how i went about it…

First of, the bike was stripped of all its plastics, the back end was fully removed to make some room to get into the cab, and air filter, just makes it better to work on also it gives me the chance to get the cleaning done on the swinging arm, the base plastics from all sides were all sanded down and given a primer.

the panels all came out really well, there all ready to get the first coat of some shinny blue.
once the panels all dried the area around the tank bust out in lots of ribs, very large embossed ribs, Not impressed with it at all, even though every care was taken to ensure this or other errors happen.

1997 Honda CR80 Re-Build Part 2

1994 BMW K 1100 LT

Marty — Thu, 07 Aug 2008 19:39:42 +0000

I bought this bike in March 2007 after a short spell with a K100,

I had to go for the grandady of them all! lol… Me and the Missus went off to france for a fortnight (May 2007) Should be great on this bike, im looking forward to it! I have included some before and after pics.

Wow what a holiday, superb,,, every day was an adventure, visited, Lile, Belgium, Amsterdam, Dusseldorf, Luxembourg, Paris, then a big biker festival in York on the way home,,, magic!

Something Else to Read?

1994 Kawasaki Zephyr 550

Marty — Thu, 07 Aug 2008 19:31:56 +0000

Ill get more details on this bike soon..

in the mean time enjoy the picture..

Something Else to Read?

1977 Honda CB 750

Marty — Thu, 07 Aug 2008 19:21:48 +0000

This chopper model was noticed when i went to buy some thing from a guy which i got on eBay,

and it turns out that the guys wife didn’t want him to have it, and we came to an arrangement were i got it for next to nothing, all the stuff again came in boxes, a few things needed a total replacement were as others were fine to use, the entire seat had to be customized to fit, a lot of problems and hacks later it was done.

I have to say it was one of the most comfiest bikes ive ever ridden.

Shug Tech » Bikes

1999 Honda Hornet 600cc Rebuild

Check out the Updated Pictures

Update 2

Update 3

Update 4

Update 5

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Another Honda CR 80 Re-build Part 1

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1998 Kawasaki KX 250

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1997 Honda CR80 Re-Build Part 3 Completed

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1997 Honda CR80 Re-Build Part 2

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1997 Honda CR80 Re-Build Part 1

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2002 MotorHispania 50cc

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1994 BMW K 1100 LT

Something Else to Read?

1994 Kawasaki Zephyr 550

Something Else to Read?

1977 Honda CB 750

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