First gear issues

[Dnyce]

Lots of ppl like ape track king clutch setup, it’s a upgrade.

 

[nintastio]

Lots of ppl like ape track king clutch setup, it’s a upgrade.

Good deal, thanks!

 

[nintastio]

Sure am glad I put in my order with Schnitz quite a while before I will actually need the parts. Been a week and still in processing.

 

[nintastio]

Realized I didn't clean out the fuel filter inside the plastic housing so I decided to tackle that today since I'm still waiting on parts. There was a bit of gunk in there but not as bad as I expected. Thought about doing the drill bypass mod but figured it wasn't necessary since it cleaned up rather well.

Got it all back together and realized the gas tank was leaking pretty good out of the feed nipple. Went through the design in my head and realize it shouldn't be able to leak unless something wasn't sealing properly. After tearing it down saw that I tore an o-ring when putting it back together. Suzuki dealer in town had to order it and wanted $12 for it.

Found it on Revzilla for $8 so went that route. Part # 15113-35F00

 

[nintastio]

I was messing about in the garage and noticed my ECU had some writing on the bottom which was partly rubbed off but possibly said 02 hayabusa on it so I did some digging. From what I have read it looks like I have the newer 32 bit ECU from a 02-07 hayabusa. I still need to look further into how exactly they did the conversion but I was pretty excited to see that with the differences in tuning options.

So the bike came with plenty of issues, but at least it has the upgraded fuel tank/pump and ECU. Should be a great bike once I have it back together. I will have to swap out the exhaust and get it properly tuned once I recover some funds. The header is smashed in pretty good on the bottom, but it will work for now!

 

[nintastio]

Finally got my package from Schnitz, put in the new large fork and buttoned up the water pump and gear selector housing. I keep going out in the garage trying to find something else to work on, but nothing left to do until the trans comes back.

I still need to figure out what I'm going to do for flashing the ECU. I'm tapped for funds for now so I have a bit of time to get that figured out. I did finally bring a table out to the garage so I'm not working on the floor like a goblin, lol.

Until then I shall keep searching and learning!

 

[Dnyce]

I like that billet fork

 

[nintastio]

I like that billet fork

I'm sure an OEM fork would have worked just fine, but I'm a sucker for shiny things.

 

[Dnyce]

Since u had to get one, definitely spent the little extra and upgrade. Mine were still good, otherwise I would’ve got em too lol

 

[Berlin Germany]

Your best bet is to just fix the one you have. Buy a good manual like climers or something and knock it out. if your not mechanically inclined, i suggest a shop.

@nintastio

that manual i guess is not the best

the best manual for gen1 is available HERE

it is the original suzuki manual

and

first time digging into a motorcycle transmission ?
man don´t start that
either you find a neighbor with lots of exp. to learn you by showing you each single step
or you join a suzuki shop

it is a damm hard job to get motor out and open and closed and in again
and in my view impossible for a newbie.

 

[Dnyce]

Eh he’ll be fine, he’s not cutting the trans himself. Just remove and replace, easy day

 

[nintastio]

@nintastio

that manual i guess is not the best

the best manual for gen1 is available HERE

it is the original suzuki manual

and

first time digging into a motorcycle transmission ?
man don´t start that
either you find a neighbor with lots of exp. to learn you by showing you each single step
or you join a suzuki shop

it is a damm hard job to get motor out and open and closed and in again
and in my view impossible for a newbie.

Thanks for the suggestion, but if you look through the thread I have the engine out, split and trans is sent off to get undercut. I may have no idea what I was doing when I started but I've learned a lot and I'm a pretty smart guy.

 

[nintastio]

We are ready to rock!

 

[nintastio]

Work comes early in the morning so I'm done for the night, but made some good progress tonight. Only had a couple hours to wrench on it but the engine is mostly assembled and so far going nice and smooth! Just following the service manual and reading everything multiple times before I move on to the next step. Fingers crossed it continues to go nice and smooth.

I work from home most days so I'm hoping to be able to spend a few more hours in the garage tomorrow. Should be able to get the engine fully assembled tomorrow then the not so fun part of getting it back into the bike.

Without the extensive knowledge you all have posted over the years there is no way I would of had the confidence to tackle this myself so thanks to all of you!

 

[sixpack577]

Finally got my package from Schnitz, put in the new large fork and buttoned up the water pump and gear selector housing. I keep going out in the garage trying to find something else to work on, but nothing left to do until the trans comes back.

I still need to figure out what I'm going to do for flashing the ECU. I'm tapped for funds for now so I have a bit of time to get that figured out. I did finally bring a table out to the garage so I'm not working on the floor like a goblin, lol.

Until then I shall keep searching and learning!

View attachment 1651598

Is that a gen1 or gen2?

 

[nintastio]

Is that a gen1 or gen2?

It is a gen 1

 

[sixpack577]

It is a gen 1

Ok, I can only do gen2, sorry.

 

[nintastio]

Ok, I can only do gen2, sorry.

I'll probably end up getting a harness from boostbysmith just so I don't have to source the connectors to make my own. But thanks for looking out!

 

[sixpack577]

I'll probably end up getting a harness from boostbysmith just so I don't have to source the connectors to make my own. But thanks for looking out!

Schnitz, Powerhouse, or Moore Mafia can flash it for you cheaper than the cost of the equipment.

 

[mabupa]

Work comes early in the morning so I'm done for the night, but made some good progress tonight. Only had a couple hours to wrench on it but the engine is mostly assembled and so far going nice and smooth! Just following the service manual and reading everything multiple times before I move on to the next step. Fingers crossed it continues to go nice and smooth.

I work from home most days so I'm hoping to be able to spend a few more hours in the garage tomorrow. Should be able to get the engine fully assembled tomorrow then the not so fun part of getting it back into the bike.

Without the extensive knowledge you all have posted over the years there is no way I would of had the confidence to tackle this myself so thanks to all of you!


View attachment 1652013

Don’t you have sick days so you can finish this thing? I’m looking forward to your first ride report after the repairs. Between this thread and @InfiniteReality build it gets pretty entertaining on the forum. Lol!