Project Streetfighter

[Kevin 1G Drummer]

It's been pretty nice lately, so I've been putting a little time into this project. First off, I installed the new exhaust system and installed the new tail light



The exhaust sounds amazing. Nice and quiet at idle, but crack the throttle and all hell breaks loose

Today I installed the new Buell headlight and got it wired in, put on the frame sliders, and bar end mirror. All I have left is to figure out how I'm going to make the brackets to mount the flyscreen, and cut up the stock windscreen.

[TkrPerformance]

that looks really good

[DSM_421]

Looking good, only thing that is missing is a turbo.

[craig]

I approve of your choices.

[Super Bleeder!!]

Good taste.

[Kevin 1G Drummer]

Originally Posted by DSM_421

Looking good, only thing that is missing is a turbo.

This bike will never see a turbo. These motors don't like boost too much. If I wanted a bike that made huge power, I would have gotten a 'Busa or a ZX14.

[Kevin 1G Drummer]

I took some time tonight after work and finally made the last bracket to mount the windscreen. I'm pretty happy with how it came out. Now I just have a couple little things to paint black, and it'll be done! for now...






It's super dirty and needs a wash pretty badly, so that's next on the list.

[Kevin 1G Drummer]

So it's been forever since I've changed anything with this, but it looks like soon I'll be changing stuff inside the engine. At the least, crank and rod bearings.

As some of you have seen in the cruise thread, the oil drain plug somehow loosened up and fell out on my way to work Monday morning, dumping out all the oil just north of the lowery tunnel. I didn't notice it till I started into the corner exiting the tunnel and the rear tire started sliding out, almost causing me to lowside.

At first I had no idea what happened. It was kinda cold, so I thought maybe I hit a slick spot or my tire deflated, or I ran over someone else's oil. Shortly after I got onto 35w southbound I started to hear a slight ticking, so I pulled off onto the 36th st. exit. By the time I slowed down enough to hear (wind noise) it was knocking pretty loud so I shut it off immediately. At first I thought the gasket blew out of the oil filter since I was just reading a magazine article about that happening, but upon closer inspection there was no drain plug in it. I threw it in the back of my brother's truck when he came to pick me up and brought it home, then went to work.

When I got off work I stopped and picked up a new drain plug and some oil for it, got home and threw it in, started it in neutral and everything sounded ok. No knocks or unusual noises, so I thought I got lucky and made it out without any damage. Wrong. Yesterday I was cleaning all the oil off of everything and decided that while it was on the stand with the tire off the ground, I'd throw it in gear to make sure there was no noises while in gear and that's when it knocked a little bit. I bumped it up to 5th gear and let the clutch out, and it started knocking like crazy so I pulled the clutch in and shut it down.

I ordered the factory service manual for it today, and I'm gonna start tearing it apart on Friday night or Saturday. Carnage pics to follow.

[311evo]

Shitty. Hopefully you can get it back on the road without to much expense.

(high compression and e85 in your future?) :P

[scheides]

Ugh that is horrible. I'm sorry dude

[twack]

sucks about the damage but glad the oil didnt cause a crash

[LingLing]

Dude, that sucks. I'm sorry to hear. I know how shitty I felt when I just tipped my CBR over, so I can imagine how bad you feel.

[Kevin 1G Drummer]

Yeah, I was pretty pissed when I heard the knocking. I wanted to kick it over, but I didn't want to cause any more damage.

As far as rebuilding it, I've thought about throwing some higher compression pistons in it, but going e-85 would be quite a costly conversion. I have no idea where I would get injectors that would fit and supply enough fuel, and tuning it would be a bitch. Plus, there aren't any e-85 stations close to where I live. So it's probably just going to get the replacement parts it needs and built right, but on a budget.

[C3L1CA]

I had the same thing happen to my bike, luckily my oil light came on quick enough that I caught it before any real damage happened.

I'd also probably pick up a new tire if you can, my rear tire was never the same after oil got on it.

Good news is you didn't low side or get hurt from it though!

[Kevin 1G Drummer]

I started working on it today but since it's cold I didn't spend too much time on it, or put too much enthusiasm into it. Worked on it from about 10:30 till about 2:30

When I started on it the only thing off of it was the lower engine faring


Pulled off the gas tank, both seats, exhaust, air filter box and throttle bodies, loosened the rear plastics for access to wire connectors, radiator, oil cooler, disconnected all the necessary wires, and loosened the chain to get it off the drive sprocket. All that's left is to take out the engine bolts and pull the motor out of the frame. Then of course tear the motor apart and see what needs to be replaced.

[Kevin 1G Drummer]

I got the motor out and half way torn down today, pics to come. Still not entirely sure what's making the noise but I'm leaning towards rod bearings. Both rods are on the same journal and there's a little side to side play on both rods which I don't believe should be normal. Hopefully I'll get a little more done on it tomorrow around dinner with the fam.

[96GST16g]

ive always been scared wtf happends if your motor locks up while goin down the high way. an unexpected rear tire lock up could possibly end up in you being squash on the pavement... just something i fret over

[scheides]

I snapped a cam in half on my fzr600 while doing about 85 on i94 through the lowery tunnel....that was NOT fun but I was able to grab the clutch before the rear tire locked up too bad. Fun times

[Kevin 1G Drummer]

Thankfully nothing here locked up. I got lucky on a couple levels with this.

Anyways, here's pics of day 1 of engine teardown. about 2.5 hours worth of taking my time and making sure everything came apart right, nothing broke, and most bolts ended up back where they came from.






Front cylinder taken apart





Rear cylinder taken apart


The end of the first day


All that's left is to remove all the stator stuff, clutch stuff, the drive gears between the crank and trans, and split the case.

[Kevin 1G Drummer]

Well, I finally got the case split today. It's for sure spun rod bearings. The mains and all the trans bearings are just fine, and the rods are barely damaged at all. I can't feel any of the grooves, but they look pretty bad, and the bearing for cylinder #1 is turned just a little bit in the rod and cap. I think I should be able to get away with just getting the crank polished. There is no scoring at all in it, just some light marks that are only visible, not able to be felt at all.

Here's some carnage pics!

Half of the case and the trans gears


the other half of the case


the crank journal




rod number one




rod number two



main journals