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Discussion Starter · #1 ·
Well now that I have my rebuild project running great, thought I'd share a few pics of the finished product. (I know, it's not a Honda...):nuts:

This is my 2005 660R with the following mods:

UNI air filter with modified stock lid, Vito's Jet Kit, Full Yoshimura RS-3 exhaust
Wiseco Piston (.20 over), Hot Rods Crank, EBC Dirt Digger Clutch
Pro Design Case Saver, Pro Design Direct Shifter
Forward Powersports +2" Axle
Maxxis RAZR Front Tires, Artrax MX Trax Rear Tires
Renthal Handlebars, ODI Rogue Grips, Moose Handguards & Deflectors
Aftermarket Nerf Bars, DG GNCC Bumper and Grab Bar, PRM Skid Plates









Took it out last weekend and it's now running better than ever, and is a blast to ride! I'm very happy with how it turned out. :hey:
 

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Discussion Starter · #5 ·
Thanks! This was a full rebuild, down to the crankshaft. The frame was bent, axle carrier was cracked, rear brake caliper was missing, cylinder was egg-shaped, the small end of the rod and wrist pin was shot among other things. It was basically a rolling barely-running basket case when I got it. With the exception of machining the cylinder and removing a couple blind case bearings, I did all the work by myself. First time going through an engine too. Relied heavily on the service manual and a friend who has rebuilt several dirt bike engines. One heck of a lot of work, but the results are very satisfying:D.
 
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