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Discussion Starter · #1 · (Edited)
Hi,

Iv'e been a silent member for some time now, mostly searching info for mods and maintenance on the 919.
Although forums seems to be a dying breed, there is some great info on here and suprisingly some activity.

So I bought 2 years ago my first bike with 24K km on the clock.
The bike was not in bad shape but the paint has seen better days. Previous owner stored it outside with little to no protection.

The day I bought it:
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First week owning this bike, I was already on this forum looking at popular mods. So far, I went through the following:
  • Bafflectomy
  • Flapper mod
  • Pair plates
  • New mirrors
  • Tail tidy (cutting down the oem unit and bending new license plate bracket)
  • Smoked LED taillight with integrated flashers
  • 520 17/44 Chain & sprocket kit
  • Luimoto seat cover with gel insert. The original was ripped pretty bad and would be a giant sponge on rainy days.馃槰
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  • Removed the Givi case and rack as I mostly ride to work and back. Kept it as it can come in handy on long trips.
  • Removed the rear grab handle and replaced with 3D printed plastic snap-in covers.
  • Spent too much time searching the great cave of Ali Baba to finally find quality motorcycle flashers from China. They are actually top notch quality and easily visible in bright daylight. E marked and called "Pazoma", probably factory rejects from the other well known brand....馃
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- FX-R 3.0 Projector retrofit with 6000K HID, would not recommend using such a bulky projector but the results are well worth it! I dont normally ride in twisties at night so the sharp projector cutoff doesn't bother me much. The highbeam floods enough light all over the place that it basically solves the issue.

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- I also just started a RC51 front end swap!
Used a CBR929RR lower clamp and needed to extend the stem by 25mm.
To mount the OEM headlight, I drilled two holes in the lower clamp for the rubber insulators and 3D printed two brackets to secure the top part. Making this front end swap fully reversible back to stock.
They bolt between the upper clamp and ignition switch and have threaded holes to mount the OEM speedo also.

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Fully bolted up it looks like this. I will be printing a plastic cover to cleanup the area surrounding the ignition. Making the speedo blend better with the clamp and also, I will integrate a new mounting point for my Quadlock phone holder.
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Hope you enjoyed my intro, feel free to ask questions.
I am open to criticism as long as it stays polite and constructive.
I will be using this thread as my build thread and post progress pictures of my various upgrades.

More to come.

Cheers!馃嵑
 

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Discussion Starter · #3 ·
Thanks, really looking forward to have it back on the road!

Tonight I spent time on SW and got busy on that ignition switch cover I was talking about.
It will be secured via the two holes in my upper clamp. I wont miss seeing them ever again.
Printer just started, I should wake up to a fresh part tomorrow!



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Oh and I also printed a gramophone intake the other day...
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Cheers 馃嵑
 

919 Rider
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Welcome.
Nice build. Great idea 3D printing the air intake.
I made a modified air intake by grafting a aluminium stack onto a cut down snorkel mount. But 3D printing the entire unit is an excellent idea. I鈥檒l look into getting one printed.
 

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Discussion Starter · #5 ·
Welcome.
Nice build. Great idea 3D printing the air intake.
I made a modified air intake by grafting a aluminium stack onto a cut down snorkel mount. But 3D printing the entire unit is an excellent idea. I鈥檒l look into getting one printed.
I took the inspiration off your bike for that intake. But I didn't want to hack into the oem intake unit.

If you want the 3D file for that intake, let me know.

Printer has finished baking my part!




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That's a really nice bike progression!! Where did you find the RC51 front end? Those seem to be rather unicorn-ish these days...Are you planning on keeping the 919 master cylinder? I upgraded mine to a 999 Brembo unit and honestly, it was all I needed to be happy with the brakes.

How did that Luimoto seat cover treat you? I'm considering something similar. I first thought about Sargent but that's just WAY too expensive, and probably more than I need.
 

919 Rider
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Glad to hear I inspired you to 3D print that air intake. You鈥檝e inspired me to get mine 3D printed.
Thanks for the offer regarding the 3D file. I just might take you up on that.
Your bike is going to look cool once you鈥檝e finished.
Well done mate.
 

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Discussion Starter · #8 ·
That's a really nice bike progression!! Where did you find the RC51 front end? Those seem to be rather unicorn-ish these days...Are you planning on keeping the 919 master cylinder? I upgraded mine to a 999 Brembo unit and honestly, it was all I needed to be happy with the brakes.

How did that Luimoto seat cover treat you? I'm considering something similar. I first thought about Sargent but that's just WAY too expensive, and probably more than I need.
I got lucky looking at FB marketplace, the guy was parting out his track bike after crashing it.
Forks were not affected, only a small grind on the axle end.
Clip-on tubes took a beating in the crash but they are still usable until new ones arrive.

For the seat, I did look at buying a used Sargent seat but with nothing available at a reasonable price.
Forget buying new, you lose all comfort with a gaping hole in your pockets.
I went the "lazy" DIY route with the Luimoto, saved myself the hassle of making/stitching a nice cover. I did cheap out on the gel insert. Found a gel pad about 30% larger, same gel, half the cost. Had enough gel to put an insert in the passenger area!

I havent looked seriously at changing the master cylinder yet. Its on the list somewhere, but I'll enjoy the current upgrades and when they start to feel boring, I'll spice things up again! :sneaky:
 

Wanna free cat?
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Howdy, LDoorP
Thanks for coming out of the shadows and sharing your creation(s). Impressive, to say the least. More pics, please!
 

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Discussion Starter · #10 ·
Finally back on the road, still needs attention tominor details. But DAMN its a completely different bike! Whoever hesitates doing the fork swap, just DO IT!

Still missing the front fender.
The one that came with the forks was bright red, so I decided to paint it black and it fish eyed really bad on me... I did go quick on the prep prior to painting.


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In what way did you find the bike was transformed?

Either way, nice ride!
 

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Discussion Starter · #13 ·
In what way did you find the bike was transformed?

Either way, nice ride!
The front end is much more responsive and accurate. I feel like I am doing less corrections when turning, it just goes where I want effortlessly. Throwing the bike left to right seems easier as well.

Feels much smoother flying over the Quebec roads. For those who drove in QC, you know what I am referring to. Just horrible road financed by our hefty taxes.

Some changes may also be attributed to the riding position that was drastically changed by the clipons.


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Discussion Starter · #14 ·
Forgot to post an update on the finishing of my printed intake.

To get rid of the print layers and smooth to an even finish, I sanded down the whole thing with 320 grit. Then exposed it to acetone vapors for about 1 hour. It melts the plastic slowly forming a skin. Then as the acetone vapors exit the plastic, it hardens back to a glossy smooth finish. Works well for printed ASA and ABS.


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2003 Honda Hornet 919
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Forgot to post an update on the finishing of my printed intake.

To get rid of the print layers and smooth to an even finish, I sanded down the whole thing with 320 grit. Then exposed it to acetone vapors for about 1 hour. It melts the plastic slowly forming a skin. Then as the acetone vapors exit the plastic, it hardens back to a glossy smooth finish. Works well for printed ASA and ABS.


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Very impressive. I know it鈥檚 a couple years later, but I wondered if you still have the files for your printed parts? I love the new intake.. I haven鈥檛 progressed to ABS on my printer but I don鈥檛 mind the layered look of PLA. If you still have the file, I would love to get my hands on it. For that matter, any 3d files you鈥檝e put on your bike, if you鈥檙e willing to part with them
 

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Bike's coming along nicely!

Any chance you could move your crash protection knob up to the nearby frame mount and away from your engine cases? Just askin'

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