Racing to make the races (pointless bike progress report)

["Dangerous" Dan K]

So as some of you know, I ended last race weekend (which was an AWESOME weekend for me) with a bang, and threw the bike across the bowl. Turns out in that crash I screwed up the transmission, among other things. That left me with a new goal for the break between race weekends: Turn a 100% stock/street EX into the new race bike. I've been going nuts on it, alternating between working to pay for crap and 10 hour days wrenching.

So far, this is a rough list of what I've done (I'm sure I'll forget a bunch of stuff)

• Swap complete front end
• Swap shocks
• Swap rearsets
• Bend left rearset back to acceptable position
• Swap clipons
• swap bodywork (except fairing, which is @ bodywork guys getting repaired)
• Oil & filter change
• Flush coolant
• Clean entire damn bike (had been outside since 06)
• Safety wire and drill almost everything
• Bleed front brake
• Swap rear wheel
• New gearing
• New battery
• Remove all street crap I don't want/need
• Rig choke
• 1/4 turn throttle
• Catch can and tubing

This is what's left, that I can think off. Somehow this list keeps growing as I get farther into the build:

• Front sprocket swap, cut new chain to proper length
• Add distilled water and water wetter (drained the coolant yesterday, then never made it by the store for distilled water)
• Replace brake pads and wire pinch bolts (bolts are drilled, new pads are @ the track)
• Clipon tube and clutch lever (on order)
• New shifter and shift rod (on order)
• Remove side and center stands (leaving this toward last since they are handy while working on it)
• New air filter (on order)
• Drill and wire banjo bolts for rear brake
• Case guards
• Matching grips
• Shock spacer (on order)
• Check valves

Next weekend seems REALLY close right now. Especially considering I really want to make Thursday practice to give the thing a shakedown and have Friday to deal with whatever comes up in the shakedown run.

I've never ridden this bike. I didn't even know if it ran and shifted until recently. Parking lot shakedown early next week (as soon as that shock spacer comes in). The real test, of course, will be the track.

And, just because I needed an extra challenge, my finger is still killing me.

Eh, I'll get it done. Hell or high water, that bike WILL be completed and I WILL be there. That said, I've already done more work to this bike than I did to the previous bike for the entire couple years I owned and raced it. This is a LOT of wrenching to me.

[BrianC]

It's amazing what some of us put ourselves(and families) thru just to race... but nothing compares to it... after last time, I was flyin' high for days after the event! Good luck bro, you'll get back what you put in, at least emotionally!

[butcher bergs]

Drill banjo bolts?

["Dangerous" Dan K]

Drill banjo bolts?

Do they not have to be wired? They were on my last race bike, so I assumed I should on this one too. If I'm wrong that'd save me some time.

edit: This bike will probably see NJMP this season, so "lrrs doesn't check it" won't cut it. I want to be able to pass CCS tech at other tracks. Yes, I know I'll need a belly pan.

[Kurlon]

Banjo bolts are supposed to be wired.

Have you checked the valves yet on that motor?

["Dangerous" Dan K]

Banjo bolts are supposed to be wired.

Have you checked the valves yet on that motor?

I should have typed "cue the walking rulebook".

No, totally forgot. Adding that to the list.

[Kurlon]

No, totally forgot. Adding that to the list.

Leave the plugs in, spraybomb the plug recesses with brake and parts cleaner, then blow out as much mung as you can with an air gun BEFORE you try and take the valve cover off again. A hand impact driver and the right bit should make detaching the water pipes from the head doable, if not have grease ready to lube them up when you go to re-install.

I'd come down and help but I'm having no luck with oncall coverage assistance yet... :/

[CBR929RE]

Banjo bolts are supposed to be wired.

Have you checked the valves yet on that motor?

CCS rulebook makes no mention of them and LRRS rulebook say it is NOT advisable to wire them.

["Dangerous" Dan K]

Leave the plugs in, spraybomb the plug recesses with brake and parts cleaner, then blow out as much mung as you can with an air gun BEFORE you try and take the valve cover off again. A hand impact driver and the right bit should make detaching the water pipes from the head doable, if not have grease ready to lube them up when you go to re-install.

I'd come down and help but I'm having no luck with oncall coverage assistance yet... :/

Thanks bud. I cleaned the shit out of that area, so that should be no issue. Getting those water pipes out has me nervous though.

Sucks about still running the show solo, hope that eases up for you soon!

[Kurlon]

CCS rulebook makes no mention of them and LRRS rulebook say it is NOT advisable to wire them.

Bah, I'm thinking USCRA tech, they make CCS/LRRS look like renewing a Maine Inspection sticker in the County...

I still wire mine just the same.

["Dangerous" Dan K]

Bah, I'm thinking USCRA tech, they make CCS/LRRS look like renewing a Maine Inspection sticker in the County...

I still wire mine just the same.

Eh, I may want to run it in Formula EX too. I'll wire them. Good to know there's no rush on that though!

[Kurlon]

Eh, I may want to run it in Formula EX too. I'll wire them. Good to know there's no rush on that though!

If you're concerned about weakening them, get a spare and cut it open first so you know where there is meat and where there isn't. If wiring for Formula EX, you'll need to wire your throttle cable to the throttle, and any adjusters inline on the cable itself.

[Slowpoke387]

Not one banjo bolt wired on mine. Bah. I'm nuts, living on the edge. Sometimes I run with scissors.

[butcher bergs]

Bah, I'm thinking USCRA tech...

That is one stupid-assed rule, IMO.

[Kurlon]

That is one stupid-assed rule, IMO.

I don't see the issue with it. It's a fluid retaining bolt, it can be a real hazard if it comes loose while racing, all of he bolts I've wired I'm not anywhere close to causing a leak when I drill flat to flat?

["Dangerous" Dan K]

If you're concerned about weakening them, get a spare and cut it open first so you know where there is meat and where there isn't. If wiring for Formula EX, you'll need to wire your throttle cable to the throttle, and any adjusters inline on the cable itself.

Holy shit, really?! Um... ok. As for where to drill, I do have a spare but would rather use it if I mess something up. I plan to drill just like the ones on the other bike are drilled.

Not one banjo bolt wired on mine. Bah. I'm nuts, living on the edge. Sometimes I run with scissors.

Pfft... I was seen last race weekend on a pedal bike riding with no helmet, an open beer and a fixed blade buck knife in my hands (no joke). I'm concerned with passing various tech inspections, that's all.

That is one stupid-assed rule, IMO.

I don't see the issue with it. It's a fluid retaining bolt, it can be a real hazard if it comes loose while racing, all of he bolts I've wired I'm not anywhere close to causing a leak when I drill flat to flat?

You drill through the entire bolt head? That's easy peasy. The ones on the previous EX are drilled through just a corner.

[Kurlon]

You drill through the entire bolt head? That's easy peasy. The ones on the previous EX are drilled through just a corner.

No, corner to corner, one flat to the next, just in deep enough to retain the safety wire.

[butcher bergs]

I've come to the conclusion that if banjos are even slightly loose, there will be fluid leaking from the washers. If it comes loose during a race then it wasn't properly tightened to begin with and was likely leaking prior to entering the racing surface.

In short, banjos are either tight or leaking.

Again, MHO

["Dangerous" Dan K]

No, corner to corner, one flat to the next, just in deep enough to retain the safety wire.

Gotcha. The ones on the old bike are from the top through the side.

[rolker]

Especially considering I really want to make Thursday practice to give the thing a shakedown and have Friday to deal with whatever comes up in the shakedown run.

Looks like Fishtail is having some racing school that Thursday instead of the typical open practice... (Maybe the NH Cycling club will let you out on track with them?)

http://www.nhms.com/schedule/

["Dangerous" Dan K]

Looks like Fishtail is having some racing school that Thursday instead of the typical open practice... (Maybe the NH Cycling club will let you out on track with them?)

http://www.nhms.com/schedule/

Damnit! Thanks for the heads up though. So I have to shake this thing down Friday, and race it Saturday?

[rolker]

Or get everything done by Sunday and shake down at BoMo on Monday?

["Dangerous" Dan K]

Or get everything done by Sunday and shake down at BoMo on Monday?

I won't even have all my parts in by Monday.

[strgt]

Down to the wire, I like it. Its like trying to see how far you can push past E on your gas guage without running out of gas.

["Dangerous" Dan K]

I'm almost to the point where I can't do anymore until my parts come in. Finished the drilling and wiring, new sprockets are on, and some other misc. stuff (some of which wasn't even done on my last bike, like drilling/wiring the bolts for the front sprocket).

About to research how to set chain length and try to do that. Sidestand is off, I'm leaving the center stand for last because it's so handy while working on it. New (GP) shifter is on.

I've had overheating problems with the other bike so I'm going to leave the radiator fan on for now. The whole assembly can't weigh more than 3lbs. Not a lot on a production bike. If the bike isn't running hot in a couple months I'll pull the stuff off. Or maybe I'll pull it now and put it back on if it gets too hot. I'm not sure, probably depends if I run out of other stuff to do waiting on parts.