SuzukiHayabusa.org

MEMBERS => MEMBER PROJECTS => Topic started by: trunkbuster on September 08, 2009, 12:12:05 PM

Title: $1500 Busa, money well spent!
Post by: trunkbuster on September 08, 2009, 12:12:05 PM
This is where I'm at, so far, with my project Busa.  I just wanted to rebuild this bike using everything I've learned as well as learning as I go.  One of the things I've learned/heard is that a 1429cc isn't something you want to use on the street too often due to cooling issues...  I have yet to experience that! I installed a second '08 Busa fan with aluminum blades on the OEM fan and will be using Water Wetter so we'll see what happens.
  Just Some of the mods:
Da Pincci Air Ride rear shock
Front lowering spools
Polished frame, swingarm and wheel edges
Reprogrammed ECU
High-velocity ported cylinder head
APE adjustable cam sprockets
Custom dash panel
Power Commander
Wego III AFR metering system with data logger
Boz Bros. Moria Exhaust
Hi-performance Cush-drive bushings
Hi-output battery
Mirage paint
 and more.
Before pic. Damage was mainly to the front but it slid on this side.
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98890_59851-1.jpg)

Another before pic. This modification was done by the accident.
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98888_54501-1.jpg)

Disassembled, about to tear into it deeper!
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98886_48881.jpg)

I started with the engine. This is a pic of the top end removed. The cylinder block was shipped out to U.S. Chrome in Wisconsin for boring and plating. It's been bored to 1429cc and has MTC 13:1 pistons installed.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Thing%203/s1281893431_98918_86771.jpg)

I high-velocity ported the head. Here are some pics of the process which involves narrowing the intake tract to increase the speed of the incoming air/fuel charge
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98907_9181-1.jpg)
During, shaping the JB Weld to the proper dimensions.
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98906_6171-1.jpg)
The finished product.
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98908_12161-1.jpg)

Removed the PAIR valve and installed kanji covers
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98916_80741.jpg)

Replaced the hydraulic tensioner with an APE manual tensioner
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98917_83741.jpg)

Pic of the completed engine showing Kanji stator cover
(http://i635.photobucket.com/albums/uu76/trunkbuster/Thing%203/s1281893431_98918_86771.jpg)


After pic of polished frame
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98893_68131.jpg)

Pic of the forks, finished one on the left.
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98891_62601.jpg)

Pic of forks installed
(http://i635.photobucket.com/albums/uu76/trunkbuster/5730_1099575531229_1281893431_27441.jpg)

Lowering Spools used in the front, took some slight modification to get it to work with the custom dash panel.
(http://i635.photobucket.com/albums/uu76/trunkbuster/FrontLowering.jpg)

The dash panel holds the air pressure gauge, ride control switches, USB port for Power Commander-to-PC connection, and emergency kill switch for air compressor. I used the cable supplied with the Power Commander beneath the dash then purchased a USB cable with female/male connectors to connect between the dash and laptop. The gauge is turned so the needle points straight up to show the maximum pressure of the pressure switch (120 psi) so it's easier to tell if it goes over the regulated amount.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Thing%203/Dashpanel.jpg)


I used an air shifter tank as the resevoir for the air ride system. A little something I added. This system will also tie in with the alarm and GPS tracker so I can lift and lower the bike with the alarm arm/disarm and lift and lower the bike as well as remote start it over the internet also.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Thing%203/AirTankB.jpg)

The air ride compressor is mounted in Tiger Racing's auxilliary battery box in the side of the sub-frame.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Thing%203/compressorhome.jpg)

Back to the engine; I did the Small airbox mod, removing the flapper valve and actuator.
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98900_59231.jpg)

Since the timing for all cylinders is now unified through the modified ECU I added a scoop to the center stacks so they act like the outter ones.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Thing%203/s1281893431_98901_62181.jpg)

I sent the ECU off to MPS Racing so they could remove all the factory restrictions, such as the 186mph speed limit and the 1st through 3rd gear timing restriction. They also enabled Big Bore Cranking to allow easier starting for high compression engines and set the base fuel map up for use with 62# injectors.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Secretweapon.jpg)

Here's a pic of my solution for the heat issue! OEM fan has aluminum blades and the fan on the right is from an '08 Busa.
(http://i635.photobucket.com/albums/uu76/trunkbuster/5730_1099564410951_1281893431_27423.jpg)

This is what my Busa currently looks like at this moment. Stopped to work on extending a friend's GSXR swingarm and what not. My swingarm is both polished and painted but I didn't want it to get scratched up so I left it wrapped up. You can see one of the 3 angle LED lights mounted on the inner part of the swingarm, there's two pointing down and two on the underside pointing in at the wheel. I painted all three calipers red and detailed the fronts with yellow paint on the raised lettering.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Nervoussystem.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/frontcaliper.jpg)

As far as the body goes, it's been painted but needs the clear applied. This is a pic of the fender being prepped. I sealed up unused holes with epoxy resin.
(http://i635.photobucket.com/albums/uu76/trunkbuster/5730_1099575571230_1281893431_27441.jpg)
Here I am installing the 3 angle LED lights on each inner side.
(http://i635.photobucket.com/albums/uu76/trunkbuster/5730_1099575611231_1281893431_27441.jpg)
here is a pic of the painted fender with the same two-tone method used on the tank
(http://i635.photobucket.com/albums/uu76/trunkbuster/Fender.jpg)


Here is the tank. I used both black and gray primer beneath the paint to give it a subtle two-tone effect.
(http://i635.photobucket.com/albums/uu76/trunkbuster/5730_1099575891238_1281893431_27442.jpg)
This is the result.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Paintedtank.jpg)

 Still plugging away!!  I have more detailed pics on Facebook under trouble.dwight@gmail.com I'll add more pics here as I go.

Okay! Did alittle work on it the other day. I test fit the nose underpan and mounted the Power Commander to it with the supplied felcro
(http://i635.photobucket.com/albums/uu76/trunkbuster/Pwrcmdrmount.jpg)
The cable reaches to the injector harness and can be grounded at the upper radiator mount. Since the programming cable will be connected between the dash and the Power Commander I won't need to access it unless there's a major problem.

Just finished the exhaust system. I painted the muffler inside and out with header paint.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Thing%203/Wrappedsystem.jpg)

I'll be mounting the exhaust system then installing the radiator, oil cooler, and air horn. Still clear coating the bodywork and when that's done I'll be working on the wheels.
Title: Re: Profile Pic
Post by: Scary-Jerry on September 08, 2009, 12:15:34 PM
Upload yer Pics at PhotoBucket and then Copy & Paste the URL or img Link in the Body of the text.
Title: Re: Profile Pic
Post by: trunkbuster on September 08, 2009, 12:52:30 PM
Thanks :D Preciate it!
Title: Re: Profile Pic
Post by: gfast2 on September 13, 2009, 05:48:42 PM
Nice job. :thumb:.Keep pics coming!+1 on photobucket.
Title: Re: Profile Pic
Post by: trunkbuster on September 20, 2009, 01:36:43 PM
Thank you very much :lol:
Title: Re: Profile Pic
Post by: trunkbuster on October 28, 2009, 10:36:57 AM
Okay, I have a few more pics of the fan modification. I used a right side '08 fan mounted at the top of the '04 radiator. The wire connectors are from MPS racing.
(http://i635.photobucket.com/albums/uu76/trunkbuster/fanmountb.jpg)
To fasten the fan I used a simple electric fan kit I bought from Autozone.
(http://i635.photobucket.com/albums/uu76/trunkbuster/fanmount.jpg)
As seen from the front, the fasteners go through the radiator and the lock tabs are attached then ends of fasteners trimmed.
(http://i635.photobucket.com/albums/uu76/trunkbuster/radiatorfront.jpg)
OEM look from the side with plenty of header clearance. You'll need to open up your fuse box and replace the 10 amp fan fuse with a 15 amp.
(http://i635.photobucket.com/albums/uu76/trunkbuster/mountedrad.jpg)

I replaced the '04 orange lenses with clear '06 ones then I replaced the sockets with a pair of three-wire tail light sockets to make them into marker/signal lights. The tail light socket fits without modification, you just need to run a lead from the license plate or tail light running light wire. The chrome bulb you can get from an auto parts store or Clearalternatives.com (http://Clearalternatives.com). Make sure it's an 1157 type bulb
(http://i635.photobucket.com/albums/uu76/trunkbuster/frtsigmod.jpg)

Suzuki made it easy to do the mod by leaving a wire up front for you to tap into. You'll connect to the brown wire, you won't need the other one.
(http://i635.photobucket.com/albums/uu76/trunkbuster/markerlightwire.jpg)
Title: Re: Profile Pic
Post by: HOS on October 29, 2009, 12:14:48 PM
Apologees ! 1st time I`ve seen this..... excellent ideas and work there  :thumb: 8)
Title: Re: Profile Pic
Post by: trunkbuster on October 29, 2009, 06:15:42 PM
Thanks! You've got a nice ride too! I'm just trying to get mine looking and running right :D Some of the work I've seen others do on this site is amazing :shock: I know mine may not compare to alot of the other builds I've seen, I just hope my own style shows in the finished product.
Title: Re: Profile Pic
Post by: trunkbuster on January 07, 2010, 02:26:33 PM
Out with the old! I Used a bridge type bearing puller to extract my old bearings.
(http://i635.photobucket.com/albums/uu76/trunkbuster/bearingsout.jpg)

I used a tool normally used on Harley steering heads to insert my new bearings.  It draws the bearings together smoothly without damaging the races.
(http://i635.photobucket.com/albums/uu76/trunkbuster/bearingsin.jpg)

Brake bleeding is easy when the tire isn't in the way, you can do both from one side of the bike. It's even easier when a syringe is used! The syringe pulls the air right out of the caliper with no mess.  Make sure you check and fill the resevoir constantly during the operation!  If you let it get low while you're doing the bleeding you'll pull air back into the system.  Oh, don't forget to remove the lever when you're done!!  If you accidentally bump or squeeze it when the wheel is off you'll have to bleed them again to get the pads apart.
(http://i635.photobucket.com/albums/uu76/trunkbuster/caliperbleed.jpg)
Title: Re: Profile Pic
Post by: trunkbuster on January 19, 2010, 09:50:59 PM
Okay, got some more done this weekend!  Finished polishing the front wheel, mounted the fender, then the wheel.  I put the lever back on this morning and the brakes still have good pressure.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Frtwheel.jpg)

Almost done with the backend too! In the pic I uncovered part of the swingarm to show the "bling" to come 8) Wave rotor on the brake side and black Vortex sprocket with stock gearing on the drive side. My friend with the GSXR I extended gave me the license plate bracket, I got an acorn plate light from ebay to light it up.  My valve stem caps are actual .44 mag casings, compliments of ebay too :P
(http://i635.photobucket.com/albums/uu76/trunkbuster/BackWheel.jpg)

Next, I'll be working on the '08 rear sets and passenger peg brackets.  I liked the shape of the '08 rear sets and they do like nice on my '06 but it did take a little bit of drilling and tapping on the shift side to make them fit.  the brake side fit perfectly!  Once they're on I can mount the chain, tighten up the back wheel, and install the left engine cover hardware. 
Till next time!
Title: Re: Profile Pic
Post by: trunkbuster on January 31, 2010, 12:15:38 AM
Okay; got the rear sets polished, brake and clutch bled, chain and wheel complete, and sprocket cover installed :)  Here's a pic showing the right '08 Busa rear set.  I think I got it shinier than the frame!  Guess I'll have to touch the frame up now :?
(http://i635.photobucket.com/albums/uu76/trunkbuster/Rsiderearset.jpg)

She's standing on her own two wheels!  Kickstand is down and air shock is fully pumped up :thumb:
(http://i635.photobucket.com/albums/uu76/trunkbuster/Own2up.jpg)

Fully slammed :shock:  Adjustable kickstand is at just the right length!
(http://i635.photobucket.com/albums/uu76/trunkbuster/Own2down.jpg)

Just a tech note:  When you adjust your chain make sure you do so when the bike is at the lowest point where you will normally do your riding. Look for high spot on sprocket (tightest point) and measure chain slack.  Make sure chain has the minimum recommended slack because when the bike is fully lifted there will be ALOT more slack.  Well, next on the agenda will be polishing the passenger pegs and then the fun task of wiring the + and - fuse blocks along with the other stuff, i.e. rear view camera and monitor.  Wifewy is on my case at the moment, gotta get to bed :|

Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 05, 2010, 02:21:20 PM
I just wanted to add a "source" list.  I don't know the reputations of these sellers but my experience with them was okay.  I'll add to this list as I go along.

www.trickedoutcycles.com (http://www.trickedoutcycles.com) Tricked Out Custom Cycles (Chrome goodies)
www.ronayers.com (http://www.ronayers.com) Ron Ayers parts (OEM parts)
www.caswellplating.com (http://www.caswellplating.com) Caswell Plating (polishing and painting supplies)
www.motoxoutlet.com (http://www.motoxoutlet.com) Moto X Outlet (Decent priced Tires)
www.compacc.com (http://www.compacc.com) Competition Accessories (Parts, clothing, accessories)
www.jdacustom.com (http://www.jdacustom.com) JDA Custom Chrome, Sportbike Parts, Custom Builds, and Apparel
schnitzracingstore.com (http://schnitzracingstore.com) Schnitz Racing (I think everyone knows about these guys)
mpsracing.com (http://mpsracing.com) MPS Racing (Specializing in Hayabusas, another well known site)
bozbros.com (http://bozbros.com) Boz Brothers (Cool exhaust systems)
rmtracking.com (http://rmtracking.com) Rocky Mountain Tracking (Cool place to make your own "Lo Jack" system!)
mototuneusa.com (http://mototuneusa.com) MotoTuneUSA (Learn how to High-Velocity port your cylinder head!)
Sweetassseats.com (http://www.sweetassseats.com/servlet/StoreFront) (Custom seat covers, you pick material and style)
Title: Re: $1500 Busa, money well spent!
Post by: Bigrod330 on February 05, 2010, 02:55:03 PM
With the air ride and tank..looks like your doing A INSTANT Up?   May not want that on a remote.  That thang will pop so fast and flip it.  Mine will actually pop up and off the kickstand if not holding on to it.  Word of wise.
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 05, 2010, 03:00:08 PM
Hey, thanks for the advice :wink: I'll be careful
Title: Re: $1500 Busa, money well spent!
Post by: _slytly_twiztid_ on February 05, 2010, 05:29:09 PM
looks good man keep it up :thumb:
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 05, 2010, 05:38:58 PM
Thanks :D
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 05, 2010, 05:48:02 PM
Is there a reason you didnt weld the pair holes? just wondering because i welded mine instead of blockoffs
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 05, 2010, 05:57:16 PM
Hi! Weld is an inexpensive option, I just don't know how to weld :?: The plates come with a gasket and there's not a lot of pressure behind the plate.
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 05, 2010, 06:36:06 PM
i understand the pressure but you spent all that time porting the head why not make the exhaust flow better?
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 05, 2010, 06:54:29 PM
(http://i939.photobucket.com/albums/ad234/wildphil69racing/0121101604.jpg)

(http://i939.photobucket.com/albums/ad234/wildphil69racing/0120102018.jpg)

these are my exhaust ports
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 07, 2010, 02:36:04 PM
In the pic is the head upside down?  Did you enlarge them or make them smaller?  Making them smaller improves the exhaust scavenging, you have the venturi effect on the exhaust side.  I wasn't sure JB Weld would hold up in there but I did think about doing that!  I decided on a less restrictive exhaust system instead.  The work I did on the intake side will help me retain my low-end power and should compensate for the lack of back-pressure from the exhaust.  I'll find out soon how it all works together; Intake Porting, ECU modifications, cam timing, exhaust system, fuel mapping.  Like I mentioned before, I haven't done all these modifications before, let alone at the same time, to one bike.  I'm learning to tie all the mods together so they function as a package.  I'm not a beginner yet I'm not an expert either 8)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 07, 2010, 03:28:14 PM
Okay, got the passenger pegs done but I still have the chain guard to go before all the polishing is complete :cry:  Here's the pics of the pegs and brackets with the exhaust plugs in place.  Although I'll never have a passenger on the back of her I still wanted to add some flava :lol:  In this first pic you can see the left "dog bone".  I had to cut a little off the end of each one to get the bike to raise higher.
(http://i635.photobucket.com/albums/uu76/trunkbuster/P1300122.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/P1310123.jpg)

I started on wiring the WEGO in the meantime, won't be able to work on it this weekend though.  Gotta install a set of jets in a GSXR :|  I was a little intimidated by the WEGO at first, thought it was too "hi-tech" for me but, after reading up on it, found it's only a few wires and the actual sensor itself and that's it!  The first pic is the tach connection made at the ECU to the number 1 cylinder wire (blue/white).
(http://i635.photobucket.com/albums/uu76/trunkbuster/WEGOTach_input.jpg)

In this pic the connection to the Throttle Postion Sensor (TPS) is shown.
(http://i635.photobucket.com/albums/uu76/trunkbuster/WEGOTPS_input.jpg)

Here is the Bosch O2 sensor in place on the left bank of cylinders to collect samples from #1 and #2.  A "free-air" sample will have to be done to calibrate the WEGO before I can fire up the engine.  Since the exhaust is new I shouldn't have to take it back out for that.
(http://i635.photobucket.com/albums/uu76/trunkbuster/WEGOO2sensor_input.jpg)

Underneath this clusterfucation of wires and tubes and next to the air solenoid is the WEGO III itself.  It's just temporary, once I've got the tune I need it's coming back out and going on my F-one fiddy so I can use "Sniper" software to tune that.
(http://i635.photobucket.com/albums/uu76/trunkbuster/WEGOIII.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 07, 2010, 03:44:04 PM
That is he head upside down...the "fin" is what i welded and shaped...they are a little smaller i just hope it worls well because i had almost 6 hours in welding and shaping to make them all the same
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 07, 2010, 03:55:43 PM
Wow! Pretty impressive :shock:  Did you have something to go by?
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 07, 2010, 04:42:40 PM
no i just did one and then made the others the same way...if you want more pics i still have my head off and i can show you more
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 07, 2010, 07:14:20 PM
Check out mototuneusa.com (http://mototuneusa.com). This guy's got some pretty radical info on that kinda stuff and more!  He's the guy that came up with the very controversial break-in theory, "Grip it and Rip it".
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 08, 2010, 02:09:39 PM
Is your bike here in "Member Projects"?
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 08, 2010, 02:48:18 PM
no its not i actually wrecked it and decided to upgrade when i was fixing it
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 08, 2010, 05:16:02 PM
Oh, sorry about the accident :( I read some other strings where you mentioned a wheel chair and broken legs, was that from the same accident?  Hope you're doin' better!
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 08, 2010, 06:17:42 PM
that would be be me!

(http://i939.photobucket.com/albums/ad234/wildphil69racing/0804092009a.jpg)
(http://i939.photobucket.com/albums/ad234/wildphil69racing/0804092010a.jpg)
(http://i939.photobucket.com/albums/ad234/wildphil69racing/0804092010b.jpg)
(http://i939.photobucket.com/albums/ad234/wildphil69racing/0804092016a.jpg)
(http://i939.photobucket.com/albums/ad234/wildphil69racing/0804092023a.jpg)
(http://i939.photobucket.com/albums/ad234/wildphil69racing/0804092023b.jpg)
(http://i939.photobucket.com/albums/ad234/wildphil69racing/0804092029a.jpg)
(http://i939.photobucket.com/albums/ad234/wildphil69racing/0804092032a.jpg)s

Those are from aug 4th 2009 and by the end of the season i was back on a bike...The day after the doctor told me to put the crutches away and walk i got back on out trainer bike(1986 honda nighthawk 450)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 09, 2010, 01:51:40 PM
It's good you didn't get hurt even worse or worse!  Poor Busa :cry:  Good job for not givin' up the sport!  Bikes are like guns, they don't kill/hurt people, the people on them do!  I have in-laws that gave up riding because a cousin got killed on a bike.  Their grandmother told them to get rid of their bikes and I guess they did it out of respect :?:  I understand that but if I was told to sell my bike because of someone in my family getting hurt or killed on one I'd have to "respectfully decline"!  Would I be wrong for that?  I don't think I'd give it up even if my wife asked/told me too :twisted:  I've been riding since before I started dating, it's part of who I am.
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 09, 2010, 08:57:40 PM
You are right in that...if your riding within your capabilities then you are safe as long as someone else does not do something to upset that...i got my first streetbike the day before i turned 18 and i fell in love! i rode dirt before that but there is no comparison to taking a corner at 100+ and grabbing a handfull of throttle coming out! Call me crazy but riding is my "drug" of choice and i would not give it up for anything!
Title: Re: $1500 Busa, money well spent!
Post by: magus on February 11, 2010, 01:59:06 PM
 :thumb:

cool project
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 11, 2010, 05:34:10 PM
Thanks alot! I got a few more pics to put on here before I dive into the wiring.  I might not be on here for a while once I start that :?
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 11, 2010, 07:41:41 PM
Okay, got the chain guard polished!  I even polished the OEM screws with white rouge :wink: The chain guard originally had a tag holder on the end of it but I liked the other one I got from my buddy better so I chopped it off.
(http://i635.photobucket.com/albums/uu76/trunkbuster/chainguardchop.jpg)

Pic of the chain guard installed.
(http://i635.photobucket.com/albums/uu76/trunkbuster/chaingrdinstalled.jpg)

Next I'll be wiring up the relays, camera, gps tracker, alarm, accent lights, etc., etc. I'm still debating that, though. I may just wire it up enough to get it running then take it back apart later to finish.  We'll see.
Title: Re: $1500 Busa, money well spent!
Post by: Pat Dietrich on February 13, 2010, 09:54:44 AM
Beautiful resurection and even better topic layout!!  :thumb: :thumb: I have done alot of polishing in my lifetime, would you try one thing for me?? Get some cottonballs and Mothers Billet Alluminum polish and go over a section of your upper frame and watch the fine scratches disappear. Maybe you are waiting till its totally complete to go over it or maybe you dont no anything about mothers billet and cottonballs, im telling that stuff works awesome and I've tried most everything. Great write up , truley impressed!!!!!! :D :thumb: :thumb:
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on February 13, 2010, 10:49:46 AM
Beautiful resurection and even better topic layout!!  :thumb: :thumb: I have done alot of polishing in my lifetime, would you try one thing for me?? Get some cottonballs and Mothers Billet Alluminum polish and go over a section of your upper frame and watch the fine scratches disappear. Maybe you are waiting till its totally complete to go over it or maybe you dont no anything about mothers billet and cottonballs, im telling that stuff works awesome and I've tried most everything. Great write up , truley impressed!!!!!! :D :thumb: :thumb:

Have you evr tried wenol? Its hard to find but is the best that i have ever used
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 13, 2010, 03:23:54 PM
Beautiful resurection and even better topic layout!!  :thumb: :thumb: I have done alot of polishing in my lifetime, would you try one thing for me?? Get some cottonballs and Mothers Billet Alluminum polish and go over a section of your upper frame and watch the fine scratches disappear. Maybe you are waiting till its totally complete to go over it or maybe you dont no anything about mothers billet and cottonballs, im telling that stuff works awesome and I've tried most everything. Great write up , truley impressed!!!!!! :D :thumb: :thumb:
Thanks for the compliments and tip :o I used to use Mothers but not with cotton balls :? I'll give it a try! If you were to see the polish job in person you wouldn't see the fine swirls in the pics, the light from the camera flash is very harsh and brings out every detail! I wish I had a work light with that type of harsh light. 
Title: Re: $1500 Busa, money well spent!
Post by: Pat Dietrich on February 13, 2010, 05:48:31 PM
Beautiful resurection and even better topic layout!!  :thumb: :thumb: I have done alot of polishing in my lifetime, would you try one thing for me?? Get some cottonballs and Mothers Billet Alluminum polish and go over a section of your upper frame and watch the fine scratches disappear. Maybe you are waiting till its totally complete to go over it or maybe you dont no anything about mothers billet and cottonballs, im telling that stuff works awesome and I've tried most everything. Great write up , truley impressed!!!!!! :D :thumb: :thumb:

Have you evr tried wenol? Its hard to find but is the best that i have ever used

yes i have and still use motheres billet with cottonballs :thumb:
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on February 14, 2010, 02:51:51 PM
Okay, this spaghetti is what I have to make sense out of :shock: The plans for everything are in my head and handwritten notes I put in a folder as I came up with ideas :idea:
(http://i635.photobucket.com/albums/uu76/trunkbuster/Spaghetti.jpg)

I found a home for the rear view camera monitor :wink: I used a swivel base with 3M tape, hope it doesn't look too "ghetto" :?
(http://i635.photobucket.com/albums/uu76/trunkbuster/Monitormnt.jpg)

These are Time Delay Relays, they'll control how long it takes for the bike to go up or down with the use of a resistor of the specified value connected.  I'm going to try 2 seconds up and 3 seconds for down first then go from there.
(http://i635.photobucket.com/albums/uu76/trunkbuster/TDRmount.jpg)

I'm putting as many electrical components on the outside of the trunk as possible, I don't like a messy trunk 8)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 04, 2010, 11:55:45 AM
Okay, halfway done with wiring :? On the right, I installed a negative distro block, accessory distro block, and marine style fuse box. Ran the wires to the side and put connectors on in case I have to take sub-frame off in the future.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Rightsidedone.jpg)

Top view of wiring. I had to put the alarm and 8 of the 10 relays in the trunk. I tried to make it as presentable as possible :P The relay on the lower left was mounted after I took the pics
(http://i635.photobucket.com/albums/uu76/trunkbuster/Beforeblackbox.jpg)

Rear view of alarm install. I used 6 relays for the alarm, 1 accessory relay, and an ECU kill relay for the GPS tracker.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Alarmnrelays1.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 04, 2010, 12:10:00 PM
Halfway done with the rear spaghetti. Finished the right side, on to the left side. I'll be installing a mystical, magical black box in the trunk! The wires hanging down are from the tail light integrator, and the wires from the up/down relays on the side. Next to them are the connectors for the camera.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Rightsidedone1.jpg)

On the left I installed the GPS tracker, the tail light integrator, and the receiver for the air ride remote control which is tucked beneath the integrator. The wires hanging loose will be going to the black box.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Leftsideinprog.jpg)

With the help of Radio Shack I built a mystical, magical black box! The innards consist of a circuit card and diodes to seperate the inputs and outputs of the time delay relays, remote receiver, alarm, and GPS tracker. The notepad shows my mad ramblings :twisted:
(http://i635.photobucket.com/albums/uu76/trunkbuster/Blackbox1.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 04, 2010, 12:18:09 PM
Putting the black box together.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Blackbox2.jpg)

Okay, got the innards done, about to close it up.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Blackbox3.jpg)

All done, complete with connectors from MPS Racing.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Blackbox4.jpg)

Black box installed and connected.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Blackbox5.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 04, 2010, 12:23:35 PM
Rear is done with the exception of the door trigger switch for the alarm. I'll be using a micro switch to save space instead of the usual pin switch. If the hump is opened while the alarm is armed the switch will activate the alarm and send a signal through the gps tracker letting me know the alarm's been activated. The alarm's shock sensor does the same thing when triggered. For example, if someone were to try and throw the bike in the back of a truck they'd activate the tracker so me and my not-so-friendly XD-9 could easily find them :twisted:
(http://i635.photobucket.com/albums/uu76/trunkbuster/Rearnearcomplete.jpg)

After the trunk trigger I'll be working on the connections for the front.  After that I'll be mounting the camera in the undertail.
Title: Almost done with wiring, ordered seat cover.
Post by: trunkbuster on April 12, 2010, 02:21:40 PM
Well, I made some changes to the wiring connections up front. Found out I don't need as many relays as I thought, just about done! I just placed an order for a crocadile skin, cognac colored vinyl seat cover from "Sweet Ass Seats". I'll put a pick of it up after I assemble it, the website is listed in my sources on page one. :kickass:
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on April 12, 2010, 05:56:29 PM
Gotta love the XD-9...i know i love mine!
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 13, 2010, 01:40:28 PM
Gotta love the XD-9...i know i love mine!
Yep! Hey, you changed your gender??
Title: Re: $1500 Busa, money well spent!
Post by: wildphil69 on April 14, 2010, 01:54:43 AM
Idk how that happened ha thanks for noticing!  :o
Title: Ignition wiring
Post by: trunkbuster on April 18, 2010, 06:41:45 PM
Okay. I started with the green connector for the ignition switch. There are a few different ways to attach the relays. I tapped into the orange lead with an alarm triggered relay sending 12 volts for the remote start feature. In the pic I started to use a relay to close the circuit between the red and orange but changed to just tapping into the orange alone. Either way will work. To send 12 volts to the ignition I connected 12 volts to the positive side of the coil and the "Normally Open" relay contact. The other side of the N.O. contact goes to the ignition. The coil is activated by the remote start circuitry of the alarm, sending a negative signal to the negative side of the relay coil.
(http://i635.photobucket.com/albums/uu76/trunkbuster/OrIgnwire.jpg)

The ignition uses the orange with white tracer and black with white tracer to ground the ECU when the switch is in the "on" position. I cut the orange/white wire in half and put the GPS ignition kill on this circuit.  I wired the relay using the "Normally Closed" poles so the circuit is only opened when the engine kill signal is sent to the relay, grounding it, causing the normally closed poles to open and killing power to the ECU. Another inexpensive engine kill methd would be to connect a switch to these wires and put it in your locked trunk. Both ways make it difficult for someone to hot-wire your bike.

Title: Remote Start/starter kill wiring
Post by: trunkbuster on April 18, 2010, 07:14:18 PM
On to the starter circuit. On the connector coming from the right grip controls I cut the main start wire (Orange/white tracer) which energizes the ECU and Fuel pump when the on/off switch is turned on, and starter motor when the start button is pressed. I attached an alarm controlled relay between the cut Orange/White wires to kill the circuit when the alarm is triggered. The relay is wired using the "Normally Closed" contacts and the trigger of the alarm sending a negative signal to the relays ground. The positive side of the relay has a constant 12 volts but is only activated by the trigger, opening the start circuit.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Startwirein.jpg)

The wire coming from the start button to the start solenoid is the orange with black tracer. I tapped into this wire and for the remote start I used the start signal going through the first relay and sent it to a second relay to close the circuit to the solenoid and act as the start button. This relay is controlled by the alarm and uses the "Normally Open" contacts which only close when the trigger is sent using the remote start feature.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Startsolenoidtap.jpg)
Title: Clutch switch wiring
Post by: trunkbuster on April 18, 2010, 07:43:36 PM
To close the circuit for the clutch switch for the remote start I tapped into both the black w/yellow tracer wires on the left side control wire harness. I connected the wires to the N.O. contacts of the relay so when the remote start feature is used the relays ground is used as the trigger and the relay coil is activated. Again, a constant 12 volts is needed on the positive side of the relay coil.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Clutchswitchwires.jpg)

I started with this...
(http://i635.photobucket.com/albums/uu76/trunkbuster/Fromthis.jpg)

And finished with this...
(http://i635.photobucket.com/albums/uu76/trunkbuster/Tothis.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/Ignwiringdone.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/routedwires.jpg)
Title: Trunk trigger
Post by: trunkbuster on April 18, 2010, 08:22:26 PM
Okay, finished the trunk trigger. Since the body is plastic I had to use the micro roller switch with a ground connection. I used epoxy/resin to mount it to the inner side of the tail trunk area.
(http://i635.photobucket.com/albums/uu76/trunkbuster/trunktrigger.jpg)

The contact for the lever is made with a bracket I took from one of the alarm relays :wink:
(http://i635.photobucket.com/albums/uu76/trunkbuster/Humpswitchstop.jpg)
Title: New seat cover!
Post by: trunkbuster on April 20, 2010, 10:24:41 PM
Okay, got 'er did! A little glue and some staples and BAM! I thought for sure my wife would go nuts when I put this stuff on the kitchen table :D
(http://i635.photobucket.com/albums/uu76/trunkbuster/Crocseata.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/crocseatb.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/crocseatc.jpg)

Not too shabby for my first time?! The instructions made it really easy too.
Title: Relay Schematic
Post by: trunkbuster on April 22, 2010, 01:34:53 PM
Here's a schematic of a relay for reference purposes. The schematic shows the poles where the connections can be made, depending on the purpose of the relay.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Relay.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 23, 2010, 11:33:28 AM
Got the tank put together and on last night! Just have to mount the siren and finish some wiring in the front then I can get the rest of the bodywork ready. I'll have to raise it back up to put the undertail on so I won't be able to work on the camera yet.
(http://i635.photobucket.com/albums/uu76/trunkbuster/wetsandtank.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/polishedtank.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 23, 2010, 02:20:44 PM
Mounted the coolant recovery tank and filled the radiator then put the air box together and mounted it.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Airbox.jpg)
Title: Bodywork phase
Post by: trunkbuster on May 07, 2010, 10:01:26 AM
I mounted a micro switch in the plastic trim on the side of the tank. The circuit closes when the tank is lifted, setting off the alarm
(http://i635.photobucket.com/albums/uu76/trunkbuster/tankswitcha.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/tankswitchb.jpg)

Installation of the rear-view camera. The camera is a day/night one with Infra Red light.
(http://i635.photobucket.com/albums/uu76/trunkbuster/cameraa.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/camerab.jpg)
Title: Bodywork
Post by: trunkbuster on May 07, 2010, 10:05:10 AM
I found a nice, little out-of-the-way place for the alarm siren. I sanded down the spot for it and used epoxy/hardener to mount it. The alarm LED is centered in the top of the dash. I used a dremmel tool to make the hole.
(http://i635.photobucket.com/albums/uu76/trunkbuster/sirenmount.jpg)
Title: Bodywork phase: Upper fairing complete
Post by: trunkbuster on May 07, 2010, 10:07:38 AM
This is what the back of the upper fairing looks like all together.
(http://i635.photobucket.com/albums/uu76/trunkbuster/upperfairing.jpg)
Title: Bodywork phase
Post by: trunkbuster on May 07, 2010, 10:12:39 AM
I put the nose on this morning. Waiting on the plastic push-pins to come in so I can mount the nose underpan. Gonna polish and wax it one more time before I put the billet mirrors on.
(http://i635.photobucket.com/albums/uu76/trunkbuster/noseon.jpg)
Title: Bodywork phase
Post by: trunkbuster on May 07, 2010, 10:16:55 AM
A view of the back right side. I wasn't too thrilled with the fit of the undertail, it's made by Yani Shiki. I have to repaint the hump and install that next.
(http://i635.photobucket.com/albums/uu76/trunkbuster/plastics.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 07, 2010, 11:26:21 AM
I should have her running pretty soon! I'll put the sound/video on here when I do. Got the nose underpan and PowerCommander mounted. Tested the electricals and, believe it or not :shock:, 99% of everything works! It doesn't lower when the alarm is armed :?: Have to go back to the relay and see what's up. I was pleasantly surprised to find out it only has 3836 miles on it when I turned the ignition on!  I ended up having to install a 300 psi air pressure guage and another air pressure switch, the old switch's cut-off point was too low so I got a higher one rated 145-175. It works now but I've got another switch coming in rated 150-300 I might try too.  I can't test the GPS yet because I've got another bike blocking me in :?  As soon as I finish that one I'll be pulling mine out and testing the Wego, GPS, and remote start. It's getting there!
Okay, it's the 21st of May and I troubleshot the lowering issue last night. I have to go back in the black box and by-pass the diode I put in to the trigger, it isn't needed there and the resistance is too high, lowering the voltage output to the relay. Gonna try that and see what it do :?
I was able to correct the arming/air ride issue on the 22nd of May. It raises when disarmed, like it's coming alive, and lowers when armed, like it's relaxing :wink:
Title: Re: $1500 Busa, money well spent!
Post by: ironmike on May 19, 2010, 01:57:07 PM
trunkbuster,

that's the most wiring I've every seen on a bike and I'v gotta say it's impressive. Wow- I might need to refer to your great pics if I decide to
add on later. Your camera and GPS devices are a great idea.

I built my busa (02-07 "frankenstein") completely from the internet, and it's bone-stock under the skin. No two components are from the same bike or place.
Everything 'plugged and played' perfectly. Though simple, it was much more fun to build than all the choppers I've done. I'm a convert.

Please keep the pics and updates coming!

(http://i47.tinypic.com/9ab6kx.jpg)

(http://)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 19, 2010, 03:15:48 PM
trunkbuster,

that's the most wiring I've every seen on a bike and I'v gotta say it's impressive. Wow- I might need to refer to your great pics if I decide to
add on later. Your camera and GPS devices are a great idea.

I built my busa (02-07 "frankenstein") completely from the internet, and it's bone-stock under the skin. No two components are from the same bike or place.
Everything 'plugged and played' perfectly. Though simple, it was much more fun to build than all the choppers I've done. I'm a convert.

Please keep the pics and updates coming!

Sharp! That's my favorite color :D Welcome to the dark side :twisted: Thanks for the compliments! Yeah, the wiring burned up a few of my brain cells so I think I'm gonna see about using Bluetooth next time :lol:
Title: IT'S ALIVE!
Post by: trunkbuster on July 16, 2010, 01:32:16 PM
Just an update. I DOUBTED MYSELF :cry: I was having trouble getting it to stay running after it started. I went back and removed the wiring for the remote start capability, thinking it was my work, but it still did the same thing. After a little more trouble shooting I found out the PowerCommander wasn't powering up anymore. I replaced that and test fired it again, same thing :shock: I was about to throw in the towel and undo all the ignition wiring work, I took a few days off away from it instead.
  The night before I started back to work on it I had a dream about what was wrong and why it wouldn't start.  The following evening I did what was shown to me in my dream, which included upping the numbers on the PowerCommander map between 500 and 2000 rpm at 0 % throttle, and it started and ran!  I had a map I got from the PC website that was close to my set-up.  After I changed my underwear :lol: I found that I had to adjust the idle a little higher and now it sounds AWSOME! The throttle response is so crisp I was amazed, no bog or hesitation at all!  Sounds just like a race bike, with the muffler :D I'll see if I can put a sound clip on here after I put it back together.  
  I doubted myself, it wasn't my wiring at all!  I'll probably re-configure it later for remote start, I left it with the basic starter kill.  So, now I can finish the bodywork and put some insurance on it so I can ride over to the bike shop a few miles away and get the safety inspection done.  I'm going to check the numbers on the WEGO at the same time to make sure I'm not running too lean.   :woot:
Title: Re: $1500 Busa, money well spent!
Post by: magus on July 19, 2010, 02:46:49 PM
trunkbuster,

that's the most wiring I've every seen on a bike and I'v gotta say it's impressive. Wow- I might need to refer to your great pics if I decide to
add on later. Your camera and GPS devices are a great idea.

I built my busa (02-07 "frankenstein") completely from the internet, and it's bone-stock under the skin. No two components are from the same bike or place.
Everything 'plugged and played' perfectly. Though simple, it was much more fun to build than all the choppers I've done. I'm a convert.

Please keep the pics and updates coming!

(http://i47.tinypic.com/9ab6kx.jpg)

(http://)

Love the color  :thumb: :thumb:
Title: Re: $1500 Busa, money well spent!
Post by: chowda633 on July 20, 2010, 12:52:58 PM
Amazing work! Great thread!
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on July 21, 2010, 02:32:42 PM
Thanks :D
Title: Re: $1500 Busa, money well spent!
Post by: dadofthree on July 21, 2010, 02:37:27 PM
Nice work, really like the windshield and nose.  :thumb:
Title: Front-end
Post by: trunkbuster on July 26, 2010, 01:44:56 PM
Here's my front end.  I'm gonna go out on a limb here and assume you were talking about the purple Busa's nose :P
(http://i635.photobucket.com/albums/uu76/trunkbuster/Fronton.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on August 24, 2010, 04:55:13 PM
6 nuts til done! I gave my friend some fairing screws, thinking I had plenty... Guess I should've counted them again :? Ron Ayers to the rescue!!
(http://i635.photobucket.com/albums/uu76/trunkbuster/6tilcomplete1.jpg)

Figured I'd take a look at the accent lights in the mean time.
(http://i635.photobucket.com/albums/uu76/trunkbuster/6tilcompleteatnight.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on August 30, 2010, 10:31:06 PM
I "borrowed" some screws from my Frankentana so I could load up the Busa and take it to my secret test grounds.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Traileredtest1.jpg)

On the ground ready to rock.
(http://i635.photobucket.com/albums/uu76/trunkbuster/Test1-1.jpg)

I took it for a few passes at full throttle through all the gears and it ran fine except for a little stumbling at WOT. I had to shut it down when the cap popped off of the coolant tank and showered me with anti-freeze. I've never had that happen before so I'm not sure what caused it. The temperature was just reaching the "normal" point. Oh, well...  Have to run some more tests and see what happens next. After downloading the numbers from the WEGO I found it was running too rich across the board, going to adjust my PC map and run it again.
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on September 02, 2010, 02:16:25 PM
Well, it still runs! I checked the coolant tank and the engine so I'm guessing there was just some air in the system when the thermostat opened that caused it to pop like that. I'll be taking it back out to test again, I modified the PC map. If it acts right then I'll get 'er registered :thumb:
In the meantime, here's another look at the before pic:
(http://i635.photobucket.com/albums/uu76/trunkbuster/s1281893431_98890_59851-1.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on September 04, 2010, 09:23:38 PM
Well, it didn't act right :cry: I'll have to take the engine back out and space the head up again, needs a new head gasket... Oh, well, something to keep me busy :shock:
Title: Re: $1500 Busa, money well spent!
Post by: magus on September 07, 2010, 02:30:06 PM
always something fucking up just to keep ya busy  :thumb:  :lol:     bike looks good
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on September 08, 2010, 06:04:50 PM
I tell ya :lol: I can't blame anybody but me, unfortunately...  Tried to save money but I'll end up spending it anyway. I'm gonna replace the head and base gaskets with thicker ones to give me an additional .010 of clearance. The head studs and nuts will be upgraded to APE heavy-duty ones too. If that doesn't work...  Anyone interested in a mostly-restored Busa :x?
Title: Testing
Post by: trunkbuster on September 11, 2010, 09:44:39 PM
Some pics from that fateful test day.
Unloading it for the test run.
(http://i635.photobucket.com/albums/uu76/trunkbuster/101_4106.jpg)

Laptop out and was about to load the map up when I found the head gasket leak.
(http://i635.photobucket.com/albums/uu76/trunkbuster/101_4107.jpg)

Quits for the day, about to load it back up... Back to the lab :cry:
(http://i635.photobucket.com/albums/uu76/trunkbuster/101_4108.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on January 25, 2011, 01:36:06 PM
Been a while but I'm in it again :)
(http://i635.photobucket.com/albums/uu76/trunkbuster/1295983135.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on January 25, 2011, 01:38:05 PM
After looking things over I found that the exhaust cam sprocket came "un-Loc tited" :td:
(http://i635.photobucket.com/albums/uu76/trunkbuster/1295983253.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on January 25, 2011, 01:41:56 PM
With the exhaust cam sprocket loose the pistons and intake valves got a little "intimate".
(http://i635.photobucket.com/albums/uu76/trunkbuster/1295983558.jpg)

It looks like it happened the last time I started it, the marks are light. I'll have to re-do the cam timing.
Title: Head
Post by: trunkbuster on March 13, 2011, 08:12:58 PM
Well, still plugging away at it!  Got it all cleaned up and the new studs are installed.  Have to do a little work on a friend's bike then I can get back to work on this thing :wink:
I am going to swap motors. This is the eBay motor I bought for Thing 3 but I'll be swapping heads and putting it in This bike.
(http://i635.photobucket.com/albums/uu76/trunkbuster/1299628446.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/1300061764.jpg)

This monster motor is going in Thing 3 when it's done.
(http://i635.photobucket.com/albums/uu76/trunkbuster/1300061562.jpg)

This head is going on the eBay motor
(http://i635.photobucket.com/albums/uu76/trunkbuster/1300061565.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 21, 2011, 11:21:50 AM
Making progress! Got the head on both motors. This one won't take too much time since I'll be using OEM cam sprockets. While cleaning it up I found a blunder I made with the valve spring buckets... I didn't check the shims to make sure they were in the pockets where they belong when the buckets slid up while the head was tilted when cleaning it :shock:! That's what actually caused the valves to kiss the pistons on the #3 and #4 cylinders.
Anyway, ATTENTION TO DETAIL next time...
(http://i635.photobucket.com/albums/uu76/trunkbuster/1303401401.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on April 22, 2011, 02:09:24 PM
Got the cams tied down! I twisted one of the bolts in half with less than 10 pounds of torque :bah: When they say 7lbs they mean 7 $%#ing pounds! Had to borrow one from the other motor...
(http://i635.photobucket.com/albums/uu76/trunkbuster/1303491257.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 02, 2011, 09:25:37 PM
Starting to look like something...  Again :tu:
(http://i635.photobucket.com/albums/uu76/trunkbuster/1304129470.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 10, 2011, 09:30:03 AM
My ebay motor came with half a clutch push-rod! I found it when I went to put my own push-rod in...
(http://i635.photobucket.com/albums/uu76/trunkbuster/1304971475.jpg)

I've never experienced this before so I had to crack open my Haynes manual to get a look at the insides before I disassembled it.  If this happens to you FEAR NOT! You don't have to split your cases to get it out.  Just drain your oil and take the clutch cover off the right side of the engine.  Remove the clutch pressure plate and push-rod bearing assembly.  Pull out the internal push rod, I used a piece of lacing wire.  
(http://i635.photobucket.com/albums/uu76/trunkbuster/1304971478.jpg)

Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 10, 2011, 09:37:44 AM
Go back to the other side of the engine and use your new/replacement push-rod and push the broken piece all the way into the rod tube, making sure you keep a grip on the new rod.  Pull that push-rod back out and set it aside.  Now, take a long piece of lacing wire and put a small hook on the end of it.  Reach into the tube from the clutch side and pull the broken piece out.
(http://i635.photobucket.com/albums/uu76/trunkbuster/1304971482.jpg)

Once you have the piece out put your pressure plate back together and make sure you clean the gasket surfaces and replace your clutch cover gasket with a new one before putting the cover back on.
(http://i635.photobucket.com/albums/uu76/trunkbuster/1304971485.jpg)

Now you can go back to the sprocket cover and put the new push-rod in and put the cover back on.  Takes all of 10 minutes, if you have the new gasket handy.  Don't forget to refill your crankcase!!
  Well, I put the battery in this morning and lowered the air ride all the way down to adjust the chain. I'm gonna put the header on this evening as well.
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 19, 2011, 05:57:28 PM
Patched a hole in my water pump, putting the fluids in and firing it up tonight :tu:  I'll be back on here with the results later.
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 20, 2011, 10:13:58 AM
IT'S ALIVE! It scared me a little because it started right up :grn:  Took a while to build oil pressure, had to shut it down and crank it for a while without starting it.  After that I let it idle until the fan kicked in at 176 degrees.  That lower temp fan switch from Schnitz works great!  Temp needle was just below half; all down pipes came back with a little over 500 degrees each on my IR thermometer; and there were no leaks, smoke or funny sounds.  I'm gonna clean it up again, put the body work on then take it over to get inspected tomorrow.  Yayee.
Title: Re: $1500 Busa, money well spent!
Post by: STUNNAH on May 21, 2011, 12:34:33 AM
 :tu:
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 22, 2011, 05:58:29 PM
ALL DONE :bike:  Not as perfect as I wanted but, over time, I'll keep tweeking it.  Thing 3 will have to top this one 8)
(http://i635.photobucket.com/albums/uu76/trunkbuster/FrontB1.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/RightsideB1.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/RearB1.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/LeftsideB1.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: BATTMAN on May 22, 2011, 08:34:47 PM
Looks good
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on May 23, 2011, 07:17:56 PM
Looks good
Thanks BATTMAN!
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on August 11, 2011, 06:13:59 PM
Broken "Dog Bones" SUCK :td:  Note to self:  Install a set of Soupy's Performance Adjustable Links :shock:
(http://i635.photobucket.com/albums/uu76/trunkbuster/1312914558.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/1312914555.jpg)

It was an odd feeling :?  As I was skidding the 100 or so feet along the road as cars were just a few feet behind and to the left of me with an 8 inch high concrete curb to my immediate right; I felt a combination of helplessness, shock, confusion, and anger :o  After I skidded to a stop, from having the back wheel pressed against the undertail, I tried to raise it using the ride control switches, didn't work... Checked the chain, it was good... Looked a little closer and found the actual problem, the shock linkage!  It happened on the way to work on a very busy stretch of road.  Luckily, a soldier in a red F-150 stopped and helped me lift it onto the side of the road.  I got a lift home from a co-worker in the same building I work in and I returned with my truck and trailer.  After I got it home I got the Katana and rode that in to work.  At work I found someone had made a fraudulent purchase with my Paypal account...  Later that day when I got home I found out my truck had a flat tire :|  So, that was probably the weirdest day I've had in a long time!!  I'm just happy and thankful the suspension didn't break 5 minutes sooner!  I was doing about 110 on a different stretch of road before I turned onto the last one.
Title: Re: $1500 Busa, money well spent!
Post by: FlatlandBusa on August 11, 2011, 10:28:38 PM
Broken lowering links seem to happen more than it should.   

Do yours look like they are cast or billet?
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on August 12, 2011, 10:03:33 AM
Broken lowering links seem to happen more than it should.   

Do yours look like they are cast or billet?
Hi, they look like billet. They were on the bike when I bought it but I can see, now, that this type of link can't take the stress of a stiffened suspension. I'm sticking to heavy-duty from now on!
Title: Re: $1500 Busa, money well spent!
Post by: STUNNAH on August 12, 2011, 11:15:10 PM
Your OK and everything else can be fixed and/or corrected... :tu:
Title: Re: $1500 Busa, money well spent!
Post by: BATTMAN on August 26, 2011, 09:31:28 AM
I bough some lowering links from a major sponsor of this site and they broke the same way.  I just so happened to be going a little faster at the time.  It didnt end pretty, but I did walk away
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on August 26, 2011, 01:30:22 PM
I bough some lowering links from a major sponsor of this site and they broke the same way.  I just so happened to be going a little faster at the time.  It didnt end pretty, but I did walk away
:shock: Daaaaamn! Glad you were able to walk away too :thumb: PLEASE tell me they weren't the same brand I just got...
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on August 26, 2011, 01:34:37 PM
Making some changes before it goes up for sale.
(http://i635.photobucket.com/albums/uu76/trunkbuster/1314383218.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: BATTMAN on August 28, 2011, 09:22:05 AM
what kind of coolant do you have in the overflow bottle?  What changes are you making
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on August 30, 2011, 01:46:56 PM
what kind of coolant do you have in the overflow bottle?  What changes are you making
Hi!
  I used 50/50 cooolant and water wetter, not sure why it changed to the color of pee :?
  The changes: Replaced the dog-bone links with heavy duty adjustable ones, took off the air-ride kit and installed an OEM shock, removed the dash plate,  in the process of putting on the dual D&D exhaust I was going to use on the other Busa, removed the WEGO III, repainting and reassembling the new undertail for use with the camera, re-wired the LED lights used with the air-ride kit so they come on with the brake lights, took off the GPS tracker, adding a passenger seat with matching cover in addition to the hump. Previously, the dual fan radiator was swapped for a single fan radiator.
  It will still have the Power Commander (in the trunk now), the high-velocity ported cylinder head, the Viper alarm with ignition kill and remote-start capability, the modified air box (small air box mod), front end lowering kit, LED accent light kit, Schnitz lower temp fan switch, MPS cam chain adjuster, tail light integrator module, rear-view camera with triple clamp mounted color monitor, and all the other exterior goodies it had before.
  I'll post another pic of it when I'm done and then it'll be up for sale.
Oh, forgot to mention the ECU will be included also. It's been reprogrammed and de-restricted.
Title: Lettin' her go!
Post by: trunkbuster on September 05, 2011, 07:48:28 PM
All done! It's For Sale. Just finished putting the mufflers on then took it for a test ride and it's smoooooth. There's a big sound difference between the megaphone and dual setup, it makes a nice low rumble now, more refined :D It will probably need to be re-mapped for the dual exhaust but it runs pretty good now.  Asking $7000 for it. Comes with everything pictured. Also included is a passenger seat.
(http://i635.photobucket.com/albums/uu76/trunkbuster/1315265294.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/1315265296.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/1315265410.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/B1partIILrear.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/1315265013.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/1315265015.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/1315265011.jpg)
(http://i635.photobucket.com/albums/uu76/trunkbuster/1315264712.jpg)
Title: Lettin' her go!
Post by: trunkbuster on September 05, 2011, 08:00:41 PM
Here's what the mufflers used to look like with the ends all painted over. When I stripped and repainted them I lost the logos.
(http://i635.photobucket.com/albums/uu76/trunkbuster/DnDpic2.jpg)

(http://i635.photobucket.com/albums/uu76/trunkbuster/1315265408.jpg)
Title: Re: $1500 Busa, money well spent!
Post by: brandon on May 10, 2012, 06:02:17 PM
wow
Title: Re: $1500 Busa, money well spent!
Post by: trunkbuster on June 06, 2012, 11:48:45 PM
wow

Sorry, I got a little carried away :?