Rebuilt Bike 1 today. Some observations.

Had a bit of a engine issue at 8K. A bit of surging. Could have been anything. got it home and as i did I got a red engine light and zero throttle response although the bike was still idling however it was not normal. Got it on the lift and just kind of stared at it before I went off to ride something else. Today I decided to address the situation. Not knowing what it was, I did the logical thing, I just replaced everything as i could not imagine the "take it to the dealer " scenario. So today I decided that since Im replacing things, I might as well replace a lot of things.
Replaced complete injector system. All pieces
Replaced air filter (p16)
Replaced coils, wires and plugs
Pulled the forks. Replaced head bearings, cleaned the triple and forks.
Rebuilt front calipers, installed new pads and 12 point Ti caliper bolts.
Pulled the MAC radiator and put a new one in.
Tossed the fairing holder and headlight. Installed Motoholder mount and ram air tubes. Working on a headlight.
Checked the valves in both heads
Changed the oil and filter
Changed the clutch plates (Barnett) its a EVR clutch and basket
Changed the front sprocket
Pulled the entire drive assembly and rebuilt everything. Installed new Sitta 41 and ERV 520.
Pulled the swingarm and replaced the Ti swingarm pivot shafts and the roller bearings.
Pulled the rear Brembo and freshened it up.
Swapped the Fuel pump.
Made a new stiffer shift rod for the TransLogic unit.
Safety wired it all back together and cleaned the thing. Done. Looked for any leaks or residue. Not a single sign of a drip anywhere.
Runs like a watch. Worst thing was the cleaning. The roads here must be horrible. I clean the thing regularly and it is apart quite a bit but it was filthy in places I didn't realize. No idea what the problem was and I could give two .....
Its fixed. The plugs looked pretty good but aster 10500 miles, the gaps were shot. They were way out. The difference with the new plugs is quite noticeable so no they at least in my case were not 15k mile plugs. The swingarm shaft on the roller side was shot. If you are running these, the chain side is going to be shot in 4K miles. This is the second one since the motor was fired. Fun day.

Forgot some pics

Jeez, those Ti swing arm bolts don't have the longevity I'd thought they would. Fair play to you Endodoc for doing all the work yourself. Only way to know it's done right.

I should just replace all the bolts with quick release pins as much time as this poor thing spends as a mule. I think I could build the thing in my sleep. Yes Ti makes a poor bearing surface. I surmise they use a roller bearing on the drive side of the arm for a reason. Oh well. Its a 5 min swap.

endodoc said:

I should just replace all the bolts with quick release pins as much time as this poor thing spends as a mule. I think I could build the thing in my sleep. Yes Ti makes a poor bearing surface. I surmise they use a roller bearing on the drive side of the arm for a reason. Oh well. Its a 5 min swap.

Click to expand...

I checked with a Swiss coating company whether TiN or DLC coating would help on those bolts. They just said "forget it"

Instead of the garbage can you can just mail all that old junk to me

Man that's a complete rebuild from what it sounds like other than an engine tear down.