Race Bike Progress thread

[Kitt]

Hey guys,
I got a good offer on my clean title 2003 GSXR 600, and I'm taking a break from the street for a few months, so I figured I should get a platform that would have some extra goodies, and be a solid race bike for a few years.

I picked up a salvaged title 2006 GSXR 600 this weekend. She is going to be a beauty. Some pics below, as well as a progress thread.

Removed:
un-needed electronics, lights, & brackets.
plastics

Installed:


Other:
charged battery
troubleshooting engine codes and no start

To be done before Loudon Classic (June 15-17):
Drill & Safety Wire:
Pinch bolts, caliper bolts, fill caps, drain plug, oil filter, header, exhaust.
Fabricate Frame Sliders
Fabricate brake resevoir mount
Repair subframe or make new one
Fit complete plastics and undertail
Repair gas tank & cover (if time allows)
Paint!!! (if time allows)
Install Graves fairing stay
Install Woodcraft clip-ons
Install Woodcraft engine covers
Install One Second Faster rear sets
Install Reversed shifter (one up, five down)
Install new grips
Install Ohlins Steering Damper
Install DynoJet Electric Shifter (if time allows)
Install DynoJet Ignition Module (if time allows)
Install DynoJet PowerCommander III USB
Install Vortex Sprockets and DID gold chain
Install SS Brake Lines
Install Hindle Full exhaust system
Oil change & coolant flush

Future plans:
Rebuild Front suspension
New rear shock
Get faster

It's going to be a loooooooong 2 weeks!!!! let me know if you guys want some time around a bike

Day 0 - 6/3/07
Picked the bike up, as well as some goodies.



Day 1 - 6/4/07
No Progress, Rained and garage was too crowded to wrench. Charged battery. Learned that the battery had gone dead by being parked on a cement floor all winter, and the current actually being drawn out through the kickstand.



Day 2 - 6/5/07
Made Jumper wire to jump couple harness wires to put the bike in "dealer mode" and got 2 trouble codes.
C23 - Tip Over Sensor
C46 - Exhaust Control Valve actuator

C46 does not effect the bike, since the full exhaust is being removed howeer C23 prevents the bike from starting. I borrowed a TOS and started the bike o make sure we'd be good when it all comes together for next week's races.

I am researching voltages the computer is looking for in each of these inputs so I can install resistors and erase the codes permanently. I also plan to make a hard-wired switch that will be mounted somewhere accessible for easy "dealer mode" control.

Stripped several unnecessary street parts from the bike.

[smf]

this looks aweful familiar where'd you pick it up?

[Kitt]

this looks aweful familiar where'd you pick it up?

fell out of some big trailer when somebody was pulling out of the pits on sunday ?!!

[Kitt]

Day 3 - 6/6/07

Made Bypass for TOS, bike will now start. $47 part is unecessary and not ordered!

C23 - Tip Over Sensor Cleared.



This was done using a pair of 150 Ohm resistors as shown below, then the plug was packed with silicon. Waterproof bypass.











Exhaust, Radiator, Left Handle Bar controls, steering damper, horn, exhaust valve actuator removed... Will most likely need to create a jumper to replace the clutch engagement switch (that requires clutch to be in to start) since the switch has been removed.



Woodcraft clip-ons installed

Power Commander arrives in mail

[s a x m a n]

did you buy power mods before suspension mods??

[Kitt]

did you buy power mods before suspension mods??

Not sure if power commander and exhaust is what your calling "power mods" I wouldn't. Simple weight reduction and the stock exhaust was bent and interfering with the swingarm. PC to me is essential to get a smooth power curve, and I swapped the one from my '03 for this one.

mike is going to click the suspension up friday morning... front end rebuild and rear shock should be happening soon... Just didn't have time before the classic.

Dyno tuning and squeezing out #'s isn't that important to me at this point.

[s a x m a n]

there's always time for suspension mods ... heheh

i'm telling ya ... its the best "go fast" money you can spend

[Kitt]

there's always time for suspension mods ... heheh

i'm telling ya ... its the best "go fast" money you can spend

I edited the post... check back... and yea, suspension is a plus... just tell me how to build the bike while it's away at GMD...

[s a x m a n]

build the bike thursday night at the track ... i'll help ya out

(=

i hear ya though ... these race weekends are close together ... but once you do the suspension and all the bumps almost disappear, you'll be thinking "why didn't this get done sooner"

[Kitt]

build the bike thursday night at the track ... i'll help ya out

(=

i hear ya though ... these race weekends are close together ... but once you do the suspension and all the bumps almost disappear, you'll be thinking "why didn't this get done sooner"

I believe you... if you'd like to sponsor me, I'll rush it down to mike tomorrow haha...

I'm a little heavier than I used to be, and my '03 has a SOFT stock set-up, I didn't click it at all... I know I have plenty of places to make up time on the track, but I feel like I'm holding back a little in the corners, because I can feel the front pushing out bad in 6 and 10, and the rear gets a littls slick rolling the throttle coming out of 6 and 12. Adrenaline chick has a pic of my bike getting sideways coming out of the bowl, and I am pretty smooth on the throttle.

[Awesome]

Many of us have run into the teens on stock suspension and engines and run them consistantly. Pushing the front in 10 shouldn't happen, if it doest then you're not on the gas like you should be and same thing in 6. If anywhere you should feel it push in 4 and 9. You don't need equipment to go fast, and blaming the bike will only hold you back. The first and best place to fix problems and improve is yourself. Other racers could hop on the same bike you or I are riding and drop 8 - 5 seconds off the laptimes without changing a thing.

[Kitt]

Many of us have run into the teens on stock suspension and engines and run them consistantly. Pushing the front in 10 shouldn't happen, if it doest then you're not on the gas like you should be and same thing in 6. If anywhere you should feel it push in 4 and 9. You don't need equipment to go fast, and blaming the bike will only hold you back. The first and best place to fix problems and improve is yourself. Other racers could hop on the same bike you or I are riding and drop 8 - 5 seconds off the laptimes without changing a thing.

Good point... I may be letting off in 10 a little, never really thought about it in 6, but I could still be a bitch from my lowside in the bowl.

My laps dropped 2 sec. from weekend 1 to 2, and 2 sec. more from weeks 2 to 3. Makes me think I'm getting better but in reality I think I'm doing worse in a couple turns, but found a better line through a couple others... Gotta get it working all together.

[s a x m a n]

the first several weekends are when big drops happen ... and as you get quicker, the issues in certain corners start to become more obvious.

the camber in turn 6 is incredible ... so I think it'd be hard to get it sideways

as I got faster through 6, 7, 8 ... turn 9 started sucking for me ... because I was carrying more speed had to figure out how to adjust for it (quicker turn in, tighterline ... etc).

being relaxed will make most of the bike movement go away at your current pace. Any tension in the arms will cause your bike to do things it doesn't want too

[Kitt]

the camber in turn 6 is incredible ... so I think it'd be hard to get it sideways

I'd agree with ya if it didn't happen! pictures and my roommate don't lie haha... it was a shock to me, I stayed on the throttle, but when the tire caught, it stood the bike up fast and almost tossed me.

being relaxed will make most of the bike movement go away at your current pace. Any tension in the arms will cause your bike to do things it doesn't want too

yea, this is something I need to learn. I'm not good at leaving things relaxed when my adrenaline is up. Is it possible I'd be more comfortable with stomp pads, and wouldn't feel the need to "hang on" as much?

[KB]

It's a dirtbike dood just ride it!

KB

[Kitt]

Day 4 - 6/7/07

Made Bypass for clutch switch assembly, with left controls removed.

This was done by soldering the 2 middle pins on the 10-pin plug together.
I then put heat shrink over the center 2 pins to ensure no arcing to another pin. Lastly, filled the harness with silicon to make waterproof.









front sprocket, wheels, chain removed... Thursday night, time to drink!

[Kitt]

Day 5 - 6/8/07

-Fresh oil change

-Vortex F&R 520 Sprockets installed (15/47)



Oil plug, filter, caliper bolts, pinch bolts - drilled for safety wire (more to come).

example:


Repaired chafed clutch cable, re-routed inside the frame (see right engine cover pic).


Installed Engine covers (left and right).




Installed SS Brakelines, front and rear... Ohlins steering damper, Graves racing stay.

Made Bypass for kickstand switch.

This was done by soldering the 2 pins together in the switch's harness... filled the harness with silicon to make waterproof.





4AM, birds chirping, time to sleep!

[The Magician]

damn ya got a lot done after i left lol. slick.

[Kitt]

damn ya got a lot done after i left lol. slick.

can you do bodywork in a full body cast? bodywork came in today!

[The Magician]

can you do bodywork in a full body cast? bodywork came in today!

lol. you mean sanding? lol. if you bring stuff over i can help you prep it up.

[Kitt]

lol. you mean sanding? lol. if you bring stuff over i can help you prep it up.

fawk... won't have time to bring it down... we'll see... thinking of a "unique" rattle can job to get me through the classic.