Sport Bikes banner

21 - 40 of 105 Posts

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #21
Installed oil pump and my Factory Pro roller bearing detent spring


Installed my original shift drum with the Factory Pro shift star




My shift forks were still in perfect shape, so reused those too


 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #22
Can't forget the oil control orifices! That would be a very bad thing to leave out


Bottom end... complete!


After applying some assembly lube on all the crank bearings, install the lower crankcase


Torque all case bolts down to spec


 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #23
Install oil pick-up and pressure release valve


Oil pan


Flip over and install oil cooler




Install shift shaft
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #24
Oil pump drive chain and sprockets


Install the outer clutch basket


Then the inner hub, then tighten the nut (94 lb. ft = FUN when the engine is out, lol)


My original (yes 177k mile original) clutch was still in great shape, so I reused it


Coat all the clutch friction and steel plates with clean engine oil before install
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #25


Install clutch pressure plate and springs, tighten to 9 lb.ft


Time to button up the top end




Cleaned the carbon off my original head and it cleaned up nicely
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #26


Easy does it when it comes to torquing a head. Lots of small increments is my preferred method


Final torque of 35 lb. ft (much better than the 245 lb. ft for the ARP head studs I usually do on the diesels, lol)


Install exhaust camshaft and line up timing marks


 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #27
Install intake camshaft and line up timing marks




Gotta torque the cam hold down plate in the EXACT sequence numbered on the plate




Rotate the engine slowly by hand to make sure no problems, then recheck timing to make sure it's dead on
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #28
And at the crank too


Looking like an engine again!




Do a quick compression test just to make sure no major problems. Not perfect, but for an engine that is cold (supposed to do it warm) and hasn't run yet, that's still pretty damn good


Install spark plugs
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #29
Reused my original water pump


The stator cover that came on the new engine had some rash, so I sanded it down to remove the scratches


Then just painted it flat black with some hi-temp paint


Install the stator back in the cover


Install the stator and cover, valve cover, and thermostat housing and hoses, and she's complete, ready to go back in!
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #30




So I hung the ratchet straps from the rafters once again, and wheeled the bike into position




Get the engine into position
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #31
Slowly lower the frame down onto the engine


Annnnd.... she's in!




Gotta tighten the engine mount bolts in a certain sequence to center the engine, then use the special tool to tighten the adjuster lock nuts on the right side


Install the radiator
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #32
Tighten all coolant hose clamps


Attach clutch cable


Fill it up with quality cooling juices


Never forget the lube


Double check level.... it takes a little more oil after a major surgery
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #33
By this point, the anticipation was absolutely KILLING me!! For the past 4 months, all I wanted to do was hear her run again. Cosmetics or anything else I wasn't worried about, I just wanted to hear her run. So I stopped there, made sure I had everything connected engine wise, bolted the exhaust on, and stuck the gas tank on. Had a gas can with a little bit of gas in it so I poured a little bit in the tank. I was just saying a prayer.... pleeeeeease start up, please start up! There were so many things running through my mind... "did I tighten that?".... "Did I remember to put that piece in?".... "Did I leave anything loose?"..... "I did put oil in right?"..... "What if it doesn't start?". Seriously all the "what if's" running through my mind at 100 mph. But, I connect the battery and all the lights come on and the fuel pump primes. I switch it off and on several times to fill up the lines with fuel. I had my fingers crossed and made this video..... it is indeed the very first attempt to start it. Watch and see!

YouTube - MOV01897.MPG

WoooooooooHooooooo!! Success!! Seriously, words can't describe how happy I was to hear her start right up and run.... perfectly. Both a huge sigh of relief, as well as a huge feeling of accomplishment, I was almost crying happy tears just to hear her run again, and something I assembled piece by piece with my own two hands. It's a feeling like no other!

So.... after she was running like a champ, I moved on to other stuff. Remember the swingarm that was all rashed up??




I sanded it down with my whiz wheel (same as the stator cover). It slowly shaves the metal down and removes the scratches little by little until they're gone


I then used some Mothers metal polish and an orbital buffer to smooth it down to a nice shine


I then used course steel wool and hand sanded for about 3 hours, slowly removing any little scratches from the sanding, and giving it that brushed aluminum finish that was on it originally
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #34
It turned out pretty damn good if I do say so myself!


There's still a small bit of rash at the very bottom.... it was too deep I'd have to sand too much. It's alot better than it was though


Apply several coats of commercial grade clear coat to protect the metal


Install the swingarm on the bike


Hey sometimes you gotta get creative when you don't have a big enough hex bit, haha
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #35
Hey whatever works, right??


After centering the swingarm, use the special tool to tighten the adjuster lock nuts




And of course the pivot bolt


Install rear wheel and rear brake caliper
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #36
OMG... starting to look like a bike again!


My fairing stay was tweaked just a little bit, mostly on the left side




So I replaced that too


Now.... my plastics!! I got them back from the body shop, and they turned out fantastic! They repaired the small crack in the upper fairing, fixed some rash and cracks in the tail fairing, and fixed a big rock chip in the hugger, then painted them all black. The headlight had a tiny scratch so he sanded that down and got it nice and clear again. Solo seat cowl was red prior, they painted that black too. All of this cost me.... nothing. I tried to pay them, they don't take it, not even for paint. Good thing for having buddies in the body shop who are also riders themselves, huh?? LOL
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #37


Got my HID bulbs and Proton flushies transferred over to the new headlight


Front and side fairings installed


Tail installed


 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #38




Well... she's back together!! Only things I was missing here were my Puig DB windscreen and the left side fairing. Waiting for both of them to arrive in the mail, but damn it I wanted to go ride! Still had my stock windscreen so I put that on, and everything was tight enough without the left side fairing, so screw it, lol. So... Sat April 3rd around 5pm or so, letting her warm up, about to go take our maiden voyage!


Rode around town staying close to home just to be safe, incase anything went wrong. Everything was perfect though.... temp was staying where it should, plenty of power, everything was smooth and crisp, no vibrations... nothing. So I get on the highway for a short bit...all good there! Make my way up to the Blue Ridge Parkway. Made a quick video just to show how good she's running. Ended up logging 110 miles before the night was over

YouTube - MOV01943.MPG

Several days later my windscreen and left fairing show up in the mail


I've always been one for a clean stock look, so I put the decals back on (still waiting on the ones for the front upper... they were on backorder)
 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #39


So today I had everything all done and got her all cleaned up. I took her up to that special place up on the BRP for some quality pix. Here's the ending result of my past 4 months of work






 

·
They call me a ride whore
Joined
·
1,387 Posts
Discussion Starter #40




I still need to get a 'new' left side fairing... this was just a cheapo ebay one to cover it up for now. Couldn't spend the $400 right now, ugh


I'm damn proud of how well the swingarm came out, hahah


New rear hugger.... been wanting one of these forever
 
21 - 40 of 105 Posts
Top