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Author Topic: $1500 Busa, money well spent!  (Read 57484 times)

Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #75 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?
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
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Offline trunkbuster

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Testing
« Reply #76 on: September 11, 2010, 09:44:39 PM »
Some pics from that fateful test day.
Unloading it for the test run.


Laptop out and was about to load the map up when I found the head gasket leak.


Quits for the day, about to load it back up... Back to the lab :cry:
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #77 on: January 25, 2011, 01:36:06 PM »
Been a while but I'm in it again :)
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #78 on: January 25, 2011, 01:38:05 PM »
After looking things over I found that the exhaust cam sprocket came "un-Loc tited" :td:
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #79 on: January 25, 2011, 01:41:56 PM »
With the exhaust cam sprocket loose the pistons and intake valves got a little "intimate".


It looks like it happened the last time I started it, the marks are light. I'll have to re-do the cam timing.
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline trunkbuster

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Head
« Reply #80 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.



This monster motor is going in Thing 3 when it's done.


This head is going on the eBay motor
« Last Edit: September 22, 2011, 05:37:32 PM by trunkbuster »
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
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Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #81 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...
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #82 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...
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #83 on: May 02, 2011, 09:25:37 PM »
Starting to look like something...  Again :tu:
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2003 Katana 7/12: Daily Rider
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Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #84 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...


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.  


« Last Edit: May 10, 2011, 09:41:47 AM by trunkbuster »
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
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Re: $1500 Busa, money well spent!
« Reply #85 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.


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.


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.
« Last Edit: May 10, 2011, 09:40:35 AM by trunkbuster »
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2003 Katana 7/12: Daily Rider
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Suzuki GSXR 750 (multiple years): Track bike
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Re: $1500 Busa, money well spent!
« Reply #86 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.
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #87 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.
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
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Offline STUNNAH

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Re: $1500 Busa, money well spent!
« Reply #88 on: May 21, 2011, 12:34:33 AM »
 :tu:
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Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #89 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)




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2003 Katana 7/12: Daily Rider
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Offline BATTMAN

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Re: $1500 Busa, money well spent!
« Reply #90 on: May 22, 2011, 08:34:47 PM »
Looks good
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Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #91 on: May 23, 2011, 07:17:56 PM »
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Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #92 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:




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.
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
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Offline FlatlandBusa

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Re: $1500 Busa, money well spent!
« Reply #93 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?
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Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #94 on: August 12, 2011, 10:03:33 AM »
Quote from: 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?
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!
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline STUNNAH

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Re: $1500 Busa, money well spent!
« Reply #95 on: August 12, 2011, 11:15:10 PM »
Your OK and everything else can be fixed and/or corrected... :tu:
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Offline BATTMAN

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Re: $1500 Busa, money well spent!
« Reply #96 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
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Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #97 on: August 26, 2011, 01:30:22 PM »
Quote from: 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
:shock: Daaaaamn! Glad you were able to walk away too :thumb: PLEASE tell me they weren't the same brand I just got...
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2003 Katana 7/12: Daily Rider
2006 Busa: "Thing 3", 1430+cc weekend bike
Suzuki GSXR 750 (multiple years): Track bike
Do, Try, or Die!

Offline trunkbuster

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Re: $1500 Busa, money well spent!
« Reply #98 on: August 26, 2011, 01:34:37 PM »
Making some changes before it goes up for sale.
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2003 Katana 7/12: Daily Rider
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Suzuki GSXR 750 (multiple years): Track bike
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Offline BATTMAN

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Re: $1500 Busa, money well spent!
« Reply #99 on: August 28, 2011, 09:22:05 AM »
what kind of coolant do you have in the overflow bottle?  What changes are you making
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