Thanks guys! Sorry for the delayed response, busy work week.
I did not do a time lapse, which is kind of sad because I have a gopro and could have easily set it up. Next time

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So, tear down and reconstruction was not that bad in terms of labor and technical complexity, you can more or less figure everything out from Partzilla.com explosion diagrams and grab the torque values and various details from a service manual.
Money wise though, it can be pretty darn expensive depending on what you need/want to do. I needed to replace just about all typical consumables as well as do all the work for the 'restoration' part, AND the previous owner had mussed up all sorts of things, so I spent a hell of a lot more than I was initially anticipating. I will not make any money off of this, but I learned a lot so I guess that counts for something haha. Here's a breakdown:
Tools
I own a whole bunch of auto tools already, all the standard stuff, this is what I needed to add to my collection:
- large size socket set (1-1/2" etc) - $20
- special socket for steering stem nut - $37 (ebay)
- Stockton chain breaker tool - $40 (50% off at cyclegear)
- Pistol puller - $25
- (4) jack stands for 'creative support' - $80
Supportive Materials
I had to build an engine hoist, I made a frame out of 2x4's and rigged up a 1-ton chain lift from harbor freight. Not cheap, but fun and most of the things besides the wood and screws are re-usable project to project.
- wood - $70
- screws - $20
- hoist - $30
- chains, threaded rods, etc - $40
Official Honda Parts
I did purchase all official Honda parts form Partzilla.com for the most part, mostly due to convenience considering I needed hundreds of one-off type things. Without listing them here (it would be impossible to remember), I'll just say, I'm a perfectionist and my goal was to take a 2006 919 and return it to a 'like-new' condition (within reason) by replacing broken and overly worn parts. My bike had 30,000 miles when I got it, it had spent a lot of time outside, lump sum was:
- OEM hardware, gaskets, plugs, wires, grommets, washers, bolts, hoses, lines, cables, etc etc etc - $700 total
Things from that list that I can remember:
- brake lines (SS)
- throttle cables
- clutch cable
- fuel lines
- some coolant lines
- some vacuum lines
- completely rebuilt both rear sets
- all visible hardware that was corroded
- rebuilt kick stand
- rebuilt shifter and rear brake
- master cylinder parts
- plugs and wires
- water pump gasket and o-ring
- frame bolts
- rear caliper piston
- seals for all pistons and various caliper parts
- choke cable
- every spring I could find
- all kinds of bolts and screws and crap like that
- more that I can't remember
Paint
If you want details on painting just ask, I spent a hell of a lot of time learning to prep properly, apply properly, cure properly, etc. You can do some pretty awesome stuff with basic VHT cans if you take the time do things right/have way to cure the paint.
- Frame paint, POR-15 base and top coat, 2 pints - $40
- Textured black - Rustoleum truck bed liner, 6 cans - $60
- Flat black - VHT engine enamel, 6 cans - $60
- Red - Duplicolor candy apple red, 2 cans - $20
- Clear coat, for all black and red colors except frame, VHT matte clear wheel paint, 6 cans, $60
- Radiator and muffler paint -VHT header paint matte black, 3 cans, $30
- (2) cans of VHT roll bar and chassis for misc - $20
- (1) can of VHT caliper - $10
- (4) cans of VHT primer for as needed - $40
Stuff you probably don't have to buy, at least not all at once (hopefully)
- Front and rear rotors
- Front and rear pads
- Chain
- Tires
- Renthal bar
- New levers
- New seat
- Fork springs and seals
- exhaust wrapping
- Turn signals
- Wiring to fix messed up integrated taillight and license pate lights
- Rebuilt entire headlight (previous owner destroyed the first one trying to make some sort of custom projector thing that mostly just killed the battery)
Sorry for the length, tried to keep it short. If you want any specifics let me know!
Charles