The 900RR project has greatly exceeded expectations. Had some fun with doing the work and learned both how to do stuff and not to do stuff. So FWIW, here’s a bit of both. In the end, I now have a classic CBR that is an excellent bike by any measure.
I started with a complete, early 900RR that I’ve owned since March 1992. I rode it for 12 years or so, then let it sit – covered and protected - while I played on other, newer bikes. Only 16K miles. So I knew the history and the mostly straightforward work that it needed. Most restoration projects probably start with bikes in need of more serious repair, so I had a bit of a head start. But even bikes with only “minor neglect” of just old age can require a fair amount of work – brakes, forks/shocks, carbs, anything with seals, and *lots* of cleaning/rust removal/repainting.
My goal was/is to restore the bike to its former condition for afternoon twisties and occasional track days. It has plenty of power and the S21s are certainly better tires than were available back when.

1. Cleaning/rust/repaint. I probably spent the most total time on trying to figure out how to make aluminum and other bits look new again. Watched lots of online “how-tos”, tried all sorts of different chemicals and abrasives and in the end got most of the bike looking pretty good. For oxidized aluminum engine parts, I found that Rust-oleum gel, followed by a coat of matt clear coat (or sometimes just some AL polish) worked well. I had good luck using small soft wire brushes such as these (Rocaris Steel Wire Wheels Pen Brushes Set Kit Accessories for Rotary Tool – AMZ, $17 for 60) to remove surface oxidation. I wire brushed all exposed fasteners, even the inside of socket head bolts. Worked great. I used a variety VHT paints on headers, muffler, calipers, engine cases etc. I used a matt clear coat on lots of surfaces. I had lots of small parts and the swingarm bead blasted to clean up exposed aluminum bits. Some pieces look brand new. Spent a lot of time experimenting, but got it mostly (not all) right in the end I think.
2. Fairings/body parts. I had previously replaced most of the plastics along with the fuel tank after I was run off the road some 20 years ago. Since I had to buy mis-matched used OEM parts from ebay I had to paint everything to match. Fortunately, I was able to get OEM graphics, but in a different color pattern that worked with the new, red paint. Frankly, I think this is a combo Honda should have done, but maybe that’s just me. Windscreen is aftermarket, tinted. I’d prefer clear, but haven’t found one yet.
3. Carbs. I knew the carbs needed rebuilding and I decided to have a local shop (RMC Moto) do them. Perhaps I could have done that work – lots of guys do, but i’ve not done carbs before so sent them out. Glad I did.
4. Brakes. I did the brakes and bought my rebuild kits from Brake Masters. Both master cylinders, front are rear calipers and new EBC pads. Brake Masters uses only Japanese and European sourced parts – I highly recommend them. Great customer service. I replaced the front SS brake lines with Core Moto lines which come with new banjo bolts and washers. I also found good OEM front rotors on ebay that i needed.
5. Forks/shocks. When the 900RR first came out, it was appropriately criticized for its not-so-great suspension. Many blamed the 16” front wheel, but that really wasn’t the problem. In northern CA and elsewhere, the standard fix, particularly for racers, was to send the forks/shock to Lindemann Engineering or similar shop for a rebuild (using Race-Tech parts, I think) AND installation of the Ontario Moto-tech triple clamps which altered the front-end geometry. The transformation was/is quite remarkable, and I had this work done not long after getting the bike. Night and day difference. I had the RMC do a standard re- rebuild and the results are excellent. The bike handles great – tight like my previous R1, but not as harsh. Far better than my 2021 1000 SX. If you’re riding your early 900RR hard, you really do need to re-work the suspension. Makes it a very different (and much better) bike.
6. Gas tank. While the tank was pretty clean, I decided to re-clean/rinse with vinegar. Bad decision – the inside of the tank was worse afterwards. Not sure why. So I used the non-acid rust remover and added some small, clean gravel to shake around and loosen any rust. Easy enough until its time to get everything out of the tank. Turned out that the shop vac was the best tool to clean the inside. All good now.
7. OEM parts. I was pretty happy to find that I could get nearly all of the OEM parts I needed – mostly small but expensive seals, brake reservoirs, fasteners etc. New footpeg rubber, fuel filter, brake reservoirs – all were available from Honda. I bought most parts from Chapmoto.com, but I think they all get their OEM parts from the same source (Honda). I did have to replace the fuel pump and bought a Quantum aftermarket pump. Manufactured in US with lifetime warranty. https://www.highflowfuel.com/ I do need 1 quarter-turn fairing fastener. Anyone?
8. Chain. I replaced the chain with a new RK gold chain mostly because I couldn’t get the original chain clean and probably damaged the 0-rings trying. I didn’t replace the sprockets like you’re supposed to when replacing the chain, but the wear was minimal, so left the originals on.
9. Electrical. I had to repair the right front turn signal and replace one headlight, but otherwise the electricals are all good. Got lucky I guess.
10. Misc. Seats are original and perfect. Grips are clean, good, as is the dash. No clock, no fuel gauge, no electronics – just a great motor/suspension in a reasonably comfortable super sport bike.
Overall, I’m really happy with the 900RR. After my extended dalliances with two R1s (the 2015 was a fantastic, though a physically demanding bike) the CBR is so much fun to ride. Am looking forward to track days to see if I can get back to decent lap times. Now that I have a sport touring bike (Kawi 1000sx) for long trips, I can keep the CBR for its intended purpose. It still is a great bike and I am really glad that I never sold it.


These are still great looking bikes

From any angle

Didn't have to pull the motor, but most everything else came off

Parts is parts!

 

That is an awesome write up. Thank you for taking the time for such a detailed post. I am sure others will find value in it

 

Looks great in that paint scheme 👍