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Steve, do you mean the lip on the bottom of the boot on the A1 models? We used to get rid of it to make the boot fit smoothly onto the throttle bodies. They removed the lip on later models I believe.
The boot on the head side, not the airbox side.
 

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Discussion Starter #22
Back to the stock timing trigger. Going to use my Scott Davis Racing ECU flash. More coil dwell. Raised rpm. 3° advance in the mid-range and 5° up top.

cmg
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Discussion Starter #24
Easy to check valve lash. All good.
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I used a .60mm shim to put a little extra squeeze on a old cover gasket.
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Changed out the weaker cam chain tensioner for the stronger late model.
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The one one the left is the late model. Stronger because the lock jaw is narrowed. Making the pin that holds it stronger. The pin on the old unit can break.

cmg
 

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Discussion Starter #25
The A model engine has a different front engine mount than the B model. But other than that it will bolt in. Going to address the issue with a piece of flat stock. 11.5”x1.5”x1/4”.
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The bare cyl head is a B model. It has both mounting bosses. Could easily drill and tap so a B model engine could be used in a 2000-2001 A.

cmg
 

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So I'm guessing you're also swapping out the wiring harness' and ECU with matching A1 parts? So you can run Scott's ECU flash?
 

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Discussion Starter #27
So I'm guessing you're also swapping out the wiring harness' and ECU with matching A1 parts? So you can run Scott's ECU flash?
Yes all A1 electronics. I don’t have any 04-05 B model components. Throttle bodies, harnesses, ecu. So, A1 will have to get the job done. :)
 

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Discussion Starter #28
Needs a quick wash.
these chassis are so light. I can easily pic this up. Front and rear off the ground. Very very light.

cmg
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Discussion Starter #29
If you ever have your engine out, it’s advisable to get the thermostat serviced, hoses, check the valves, replace vacuum lines, etc. The caps on two vacuum nipples were weathered and cracked. Obviously it’s so much easier.
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Needs a quick wash.
these chassis are so light. I can easily pic this up. Front and rear off the ground. Very very light.

cmg
you picked up my turbo bike to unload it once lol. i would think a chassis is just a one handed warm up for you!
 

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Discussion Starter #32
Getting old now, so the chassis work out is enough...lol
OCD is a lifestyle....lol

ram air doesn’t work when there is a huge hole in the air box. 03-05 frames all have this hole. ??
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So...a little piece of aluminum and a good squeeze of rtv. I put a extra squeeze in the middle to push through the hole. Should hold.
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cmg
 

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Discussion Starter #34
Another hole in the air box has to be addressed. The kleene system hose hole.
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The factory grommet with a few bits works great. I use a lock nut and a dab of rtv for ocd.
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Indecently, if in the back of your mind you would love to turbocharge your 12, sealing up the frame is pretty straight forward. A little more effort than this for naturally aspirated. That hole in the front of the airbox is a pia but everything else is basic. The A1 frame does not have that big hole in the front. I’ve not seen a 2001 or 2002.

Engine went in with no hassle. The floor jack is great. Harbor Freight. ?
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Discussion Starter #35
Forks off. Polished up the chrome with 1000 grit. Greased the lower seal. Before the lube the outer was dragging bad on the inner tube. Much much better after the clean and lube. None the less, these forks have a lot of sticktion. Dumped the oil, pumped the fork and got a little more. One fork had 400ml and the other 350ml. The manual calls for 0wt??? Was that a mistake? The A1 fork calls for 10wt. I couldn’t find anything definitive here with the search. I couldn’t readily find 0wt fork oil. Traxxion Dynamics use 5wt. So 5 it is. I used 420ml.
Pumped them up and sealed them. The rebound circuit is terrible on these forks. All the way in or all the way out didn’t change the way they felt. My test sure wasn’t very scientific though...lol
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We put 5w in my brother's stock forks, which is what I thought the manual asked for?!
I've got Traxxion Dynamics cartridges in mine and use the recommended Maxima 7w
 

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Discussion Starter #37
We put 5w in my brother's stock forks, which is what I thought the manual asked for?!
I've got Traxxion Dynamics cartridges in mine and use the recommended Maxima 7w
The 04 manual definitely said 0wt. I hope the 5 will be an improvement. Do you like the cartridges from TD? Scale of 1-10 over stock?

cmg
 

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The 04 manual definitely said 0wt. I hope the 5 will be an improvement. Do you like the cartridges from TD? Scale of 1-10 over stock?

cmg
Have had the AK20's in for quite a few years now.. Complimented the Ohlins shock which I'd installed probably 6 months prior, which has the A spec 110 spring.
But to compare to stock, eg my brother's bike, I put in heavier springs at the same time and with it all together I'd say easy 8+/10.
Now, did I actually need them? Not really, but I've wasted money on worse things!
 

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Discussion Starter #39
Had to pull the snap-ring to get the bearing seal out. The other side doesn’t have the ring. With the seals out I packed the bearings with fresh grease. Push it in, spin the race. Repeat. Have to be careful when prying the seal out. Easy to bend. Also easy to flatten if you tweak it.

cmg
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