Fixing oil suckage in 2003 (project for a friend)

[Jaegermeister]

Awesome find. Can't wait to hear it purrrr.

[mattrat]

Advice needed here - The welder told me to pull all electronics(he said computers) from the bike - I assume I don't have to remove the whole wiring harness...but is there anything besides the PC3 and the EcU that needs to come out? (like hidden behind the front cowl or something?

[mattrat]

There is a smaller wired box on top of the ECU - I think this is the "mode selection coupler"? - is this a computer that would be killed by aluminum welding?

[BA BUSA]

I would remove the instrument cluster and the rectifier (under the tail section)
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[Jaegermeister]

just remove the subframe, triple clamps, swing arm, tank and kickstand.

[dadofthree]

just remove the subframe, triple clamps, swing arm, tank and kickstand.

Just take the frame eh

[Jaegermeister]

Just take the frame eh

No need for a trailer then.

[dadofthree]

No need for a trailer then.

At least you're a good sport.

[Jaegermeister]

I had bearings blow apart at 100mph on my GSXR750, on the FL turnpike, 100 miles from the truck in Orlando. Had to bring the bike all the way back to TX and it never moved again. So all this is cool.

[mattrat]

Thanks - I'll pull them tomorrow.

This is the small box I was asking about - labeled "mode selection switch coupler" in the manual - I can't see where it can be unclipped - does this need to come out?

Loaded up and ready to go to the welder:

(of course now it will be less a few more pieces before driving to town!)

[mattrat]

rectifier, Instrument cluster, ECU, PC3, and engine are all out. Gonna have to wait a day for the welding, as my wife took the truck today!!!

[mattrat]

going to pick up the frame from the welder this morning - the new valves came in yesterday and I reassembled the head. Having a little trouble getting the timing set - keeps wanting to jump a tooth - I need a third hand!

[Johnnycheese]

no you need zipties

[mattrat]

no you need zipties

got 'em -

I think the problem is with the tensioner - I need to make sure it pops all the way out before I turn the engine - I'm going to try poking it with a screwdriver before I re-install the spring, to make sure the chain is taut before I cut the zip ties.

[mattrat]

motor is done - what I did to overcome the timing skip problem was to tighten everything down and turn the engine just slightly with the zip ties still on and heard the tensioner pop - then I cut the zip ties and it was fine.

waiting on an engine bolt and I should have it all sorted by the end of the week (knock on wood)

[mattrat]

got the engine back in and re-assembling - I anticipate starting it up tomorrow and riding early next week (still waiting on the new engine bolt)

I guess we'll see if the new valves fixed the problem (fingers crossed)

[BA BUSA]

Did you check the valve guides ???

[mattrat]

^^ talked to a few people about that - I checked the ID with them still installed, and didn't see any scoring or deposits on them. I did not have the tools available to pull them and replace them.

[mattrat]

Well, bad news. Knock is still there and my abilities are tapped, as is the budget for the project. Jaegermeister and I are discussing what to do next...It is possible that this is going to go up for sale - do you guys think parting it out is a better solution than selling it as a whole? I think selling a bike with an engine knock will be difficult - and I can dismantle it pretty easily and if we sell off everything but the head, it should be fine?

opinions welcome...nothing has been decided yet.

[Jaegermeister]

I just posted a Craigslist ad. Time to begin turning this project into a profit center. If anyone sees anything they like or want speak up. Lots of custom stuff. Power Commander III, Alien Eyes custom LED tail with LED flashers, mirrors are custom with Kanji etched into glass that flashes with turn signal, custom matching seats and all the other parts. Uninstalled 530 pitch 112 link ZZZ EK chain & master link, new 40 rear sprocket, 17 front, and a 49 rear sprocket. Custom plate mount on swingarm. Pistons have new rings. Prices will be quoted in email replies. ??? Just PM me or Mattrat.