[SteveW]

It would be cool making a throttle map that pours the throttle on real nice without overpowering first and second. Would be fun to work that control out with the secondary flies. I’d love to see the woolich flash project !!

cmg

I've had a bit of a play with it on my 2006 bike, just need to spend a lot more time..
Also, just picture flicking a switch on your bars on the fly, and the secondary butterflies just go back to the stock settings again

 

[SteveW]

Reverse tightening pattern to loosen and remove cam cap bolts. I've got my special numbered bolt holder!

Cam cap off!

Alternate use for egg carton!

I was able to shift 4 shims around, just need to order another 4

 

[Duck00]

Very inventive MacGyver!

 

[color me gone]

Cam journals look nice. Motor in very nice shape.
thought of installing a intake cam on the exhaust side?

cmg

 

[SteveW]

I had considered installing an intake cam on the exhaust side, but I haven't found any available!
Plus I'm not sure how much of a gain I'll get with a completely stock motor?
Maybe if I was doing some head porting work, but not really looking at that at the moment..

 

[SteveW]

I had a good look at the velocity stacks.
The Keihin equipped B3,B4,B6 models have a bit of a lip moulded into the end of the stack.

I got the dremel out, I basically took the material out to this line, which I measured and compared to the throttle body ID.

Here's the lip

Here's no lip!

 

[color me gone]

Very nice. Excellent pics too.

cmg

 

[Duck00]

Had the same lip on the A1, I took that off too.
Now have Bear's stacks (short).

 

[SteveW]

Had the same lip on the A1, I took that off too.
Now have Bear's stacks (short).

I figured they would have similar, but I've never seen an earlier vstack.
The Keihin throttle bodies "supposedly" have a different (larger) inlet diameter to the earlier Mikunis, although they're still 46mm at the butterfly

 

[SteveW]

Good thing I had the injectors cleaned, one wouldn't even spray when first set up!
Before:

After:

Yes #1 is down a couple CC's in that image. Wasn't concerned.

 

[color me gone]

Very nice. Good to go now.

cmg

 

[SteveW]

Clearances done, tensioner reset.
I did change 8 shims in the end.

All is good. I've already got all the new seals here to put the cam cover back on.
But start-up will still be delayed as I'm waiting on more bits and pieces to arrive from Japan.. Its a bit slow at the moment...

 

[color me gone]

Looks great. Cam gears appear new!

cmg

 

[SteveW]

New seals (with part numbers)

Quick comparison showing the squish between the old and new spark plug hole figure 8's

All closed up!

Nice rubber bung I've got to seal the hole from the KLEEN hose that goes to the airbox. Just add some RTV:

Go from the bottom, sits in this hole:

This hole in the front of the frame/behind the steering stem is huge! Not sure what to do yet, I cant even reach it to plug it.. Might try something when I remove the triple tree's when I regrease those bearings...
Gotta get the wife's vacuum cleaner in here too, get some dust out!

I like how the Yoshi headers have the balance tubes 1-4 and 2-3. Keen to see what power these make compared to the Akro system on my other bike

 

[SteveW]

Ooops
Snapped a bolt head off when removing the thermostat housing!
Wish me luck...

 

[color me gone]

Oh no !
Never fails….

cmg

 

[SteveW]

Got it with the vice grips. Fought me right until the last thread

 

[Duck00]

Geez that was lucky!

 

[SteveW]

Back to the airbox hole...
I managed to roughly measure it, approx 15mm. After looking around for plugs etc at the hardware store, this is what I came up with.

Grabbed a spare Well-Nut from stock undertray.

Checked the squish diameter and it looked to me like it would work.
With a few socket extensions and uni joints I did it up as tight as I could. Took a bit of fiddling but it's in there nicely and wont budge! I think its done the trick. I thought about using RTV, but incase the fitment wasnt quite right, I decided not to. I'm not worried, but I'll have a look from inside the steering tube later, when the triples come out.

You may notice something else..

Yes there's well nuts that go into these holes too, but I always find there's too much flex in the plastic and I think the well nuts may not sit in and seal completely.

A couple of 16mm "chair tips" fit nice and tight over the stub that protrudes into the airbox. What could possibly go wrong?!

 

[Duck00]

Again, great McGyvering!