Project Hayabusa

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My build on this bike has been a work in progress for some time and finally this year I am gonna tear down the bike and build the chassis.

Some of these post are old and I copied them so you can get the whole story of how things with the bike have progressed since my purchase date.

Since I bought the bike I have set my personal best time and time again, along with a few records at Bonneville.


I bought this for $2700 it is an 03' Hayabusa with 11500 miles on the clock. The bike has a salvaged title as it was laid down on its right side. It only had minor damage to everything else on the bike with the exception of the fairing.

Here it is stripped down and almost ready to race in the unfaired class.

Once I start building the bike it is going to see major changes, starting with a custom frame that I will build from scratch and lots of other custom one off parts to make her go fast. Eventually when the chassis is done and the stock motor is bolted up and ready to run I will add a turbo system with more one off parts in hopes of making 500 horse. I plan on going really fast on this one.......it's just gonna take some time until I get there.

 

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Since finding out that the motor only had 11500 miles on it I have been anxious to get the bike down to the dyno. I was hoping it would make decent power and I was hoping to find out if there were any internal mods done to the motor. I took the bike down to MDR and made a few passes amd was pleased after my runs to know that my motor is good and making 151 hp and 92 ft tq.

I only made a few passes just to test the motor and to get a baseline as I plan on a big tear down of the motor in the future. So far my $2700 Hayabusa is getting sweeter by the day!

Scott

 

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I raced the busa at El Mirage so I had some stuff to get ready so it would pass tech.

I had to take the wheels off to balance them and put in metal valve stems.

Finished the saftey wiring

Steering stops

Home made kill switch

I had to put metal valve stems on the wheels

Here is my home made thrity minute battery hold down.

I cut the mud flap, license plate and blinkers off.

I am running with no mufflers so I have to extend them a little to get the exhaust away from my feet.

I cut some exhaust tubing and notched it in 4 places

 

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I will put an exhaust clamp on to hold it in place.

Here is all of the stuff I removed off of the bike today...........I sold a bunch of the stuff I orginally took off of the bike and made about $600, so $2700 Busa is now a $2100 Busa.

 

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I took the gas tank and air box off so I could get to the plugs and injectors.

I removed the injectors, I am giving them to my friend Kent who is going to send them off to his friend to check them out. It is possible one of them is clogged or blocked as the bike has been running weird.

Took off the radiator and oil cooler as well so I could install my new Yoshimura SS header.

Old header is removed and I am giving it to my friend Kent for all of the help he has and continues to give me.....

Here is what the bike looked like after a few hours

Kent is making me a pan for the seat so I can get my big ass out of the wind and I am going to fill the void in front of the seat with a hand built gas tank.

I got my new airbox and air ducts from Kent at Airtech and have started the installation process. Looking at my stock box and my stock ducts this should provide a lot more air.

 

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My injectors have been cleaned and calibrated. I had one injector that had a "fair" pattern and was flowing a low volume of fuel. The other three were good, all are now excellent.

Stacks installed

 

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It took all week for me to gather all of the small items to make everything come together. It always seems like when I am building a bike it is all of the small special items, misc nuts and bolts that break the bank and take the longest to get.

Got the bracket from the stock seat mounted to the seat pan.

Weather stripping instead around the ducts for a good seal

And the inside as well

The second set of short stacks are installed along with IAT sensor.

New Yosh header installed, along with the oil cooler and radiator

Bodywork is complete from where the previous owner wrecked the bike. I will paint it tomorrow.

To save time I borrowed this tank from my friend Kent at Airtech. This was Noonans old tank, but I do not think it ever made it to a bike as I had to have a bung welded in for the gas cap.

Also had to weld in the flange for the stock pump, my friend Shannon did all of the welding as I suck at welding aluminum.

Stock pump installed

 

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Tank installed! The tank was designed to sit lower, however with the stock pump it made it sit up a few inches so I made spacers to mount the tank to the old tank mount location. It works well and I can get way down on the tank and aribox.

I got the bike fired up today and took it for a test run! I am very happy with the way the bike is running. I hope to get to the dyno before next week so I can flash my ecu and make a few changes. The injector cleaning definately helped as the throttle is smooth and crisp, the bike seems more responsive and I believe there is some more power there.

A big thanks to J. Noonan, B. Moreland, K. Riches and R. Nelson for all of there help and support.

 

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I had to cut part of the mid-pipe to accomodate my megaphone. Also welded in the 02 bung for my data logger.

After I finished the bodywork repairs I painted everything.

Front view of the bike

Side **** with everything painted. I still need to make a bracket to support the megaphone. The exhasut sounds mean, but then again all busa's sound mean. I also need to flash the ecu and get down to the dyno.

 

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Here you can see I washed the bike, painted the megaphone, and finished the bike numbers and class designation.

I put the bike on the dyno to check A/F and it made a 160 hp.......once I get the ECU flash figured out I will go back and do some tuning. I am sure there are a few more hp in there somewhere.........I wish there was a way to simulate the ram air while on the dyno to see how the top end is at wide open throttle in sixth.

 

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At this point I put another intake cam in the bike and made 170 hp...........went to Bonneville and set a few records.

 

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After getting back from Bonneville I put the fairings on and ended up with a top speed of the year of 185 mph nad some change.



Here is what the bike looked like.

 

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Here is my new bodywork for the Busa, this bodywork will be used in conjunction will the tube frame chassis.

I also bought a turbo set-up........

 

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My tubing bender needs a stand!!

Here is the bottom mounting location, the smaller piece bolts to the top of your mount. I am going to build my own stand as I don't see the need nor do I have the money to spend for a $120 stand from JD2.

A 3"x3" piece of square tube will be used to get to the height of 40"

Cutting the square tube, this takes awhile to cut but the benefits are a square cut.

Square cut

Here is my 9 x 9 mounting plate and my 3 1/2 x 7 top plate. I went a 1/2 inch over on the top plate so I would have a 1/4 on each side for welding. Also not the cut-off wheels, both were new before I started. One of them got away from me and yanked the grinder out of my hand and onto the floor. Good thing I had my gloves, faceshield and safety boots on. That 1/4 steel is not joke.

Here is the idea, the bender will mount to the top small piece and the base plate will be secured to the concrete floor via red heads.

I still have holes to drill in both pieces, welding and painting. Its small progress on a big project.

 

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I used a fender wahser to mark all four corners of the base plate so they would all be the same.

I then marked the mounting plate.

Drilled some small pilot holes.

Then drilled the holes to 1/2 inch

Then to 13/16ths for the 3/4" bolts. The finger is for referenece of how large the drill bit is.......had to drill really slow with that bit.

I then grinded all of the rust and any contaments off down to bare metal for welding purposes.

I then tacked the mounting and base plates into place.

 

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Final welding....man am I rusty I haven't welded in over a year.

The almost (need anchor bolts) tubing bender stand.

 

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Picked this set-up real cheap from a fellow club member and racer. This should help in the HP department!

 

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After work today I stopped at my friend Randy's shop and he helped me start to build my upright to hold the head stock for the frame. We used a 3/8s end mill for the slots and a large holesaw for the 4 bigger holes.

It is not finished, but this is how it will stand. The larger holes are for access to the back side of the slots.

The upright is 3x3 and the small piece at the bottom is 3.5x3.5

The 3.5x 3.5 piece we be used to determine the head angle and will slide up and down on the upright when I am finished.

First I need to cut it in half so I have to right angles and then make a few more cuts and drill a few holes.

 

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Started to build the build table for the chassis

Frame work is done and on wheels

 

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Here is the almost complete table. I am pretty beat from building this and being sick. I still need to add risers in the center of the table to keep it from sagging. The last bike I built on a table like this made the center sag. As the table sits it is level from left to right, however from front to back it is slightly off. I am not sure if it is the table or the floor and I didn't check as I plan on using screw jacks at each end of the table to completely level everything prior to building.

Here is the unfinished upright for the head stock with the motor in place. I will finish the upright later.