Stefann

Enjoyed reading your journey. Quiet a ride!

Anyways, I have the exhaust and filter bolt on too. Torque is definitely improved. Still getting used to the note.

The bore would come on next week I guess.

Keep your updates coming. I would do it too here, if there is something to add i.e if you don't mind.

Good luck!

No problem, post away, we ordered and received our kit at the same time!


Ok the FFE has been installed around 4 days back, had a good 100km round trip, mileage sucks, was WOT pretty much all the way, even when I am using the car, I have to take a ride when I get back home.

Now the power bump from the FFE with the DB Killer is pretty descent, the exhaust note has mellowed now and is pretty ok, deep, throughty and still loud, although I don't like the attention, it's acceptable, will have to give it a shot without the DB Killer.

Trying to find some free time to get the big bore and air filter installed, looks like next Thursday is my best best shot for the install.

I am planning to go by the Motoman's methods of a hard run in, for this I require 2 sets of oil filters and just over 2 litres of mineral oil, all gasket are to be replaced also, I need to fit a new exhaust gasket as well when we fit the big bore kit. Will do the 50km run in with the big bore/ffe and air filter fitted, then change the oil and filter. Will fit the camshaft a little later as the run in procedure I will use will be a little different, this again will require an oil change before the run in and one straight after and obviously will change the filter at the same time, only this time the second oil change will be with semi synthetic.

Why am I going to use this method?
Firstly, it's about time, I don't have much free time, secondly there is enough evidence to substantiate motoman's methods, whilst some people (ignorantly) think his website is a money making racket, it's not, all of the information on his site is 100% freely available.

His method is not about thrashing the crap out of the bike, it's all done in a controlled manor, on this bike the max I will need to go is around 8k rpm, the only problem is that from where the mechanic I use is based, there is an incline within 5-6km in all directions.

Anyway time will tell whether or not this method is good or bad, I am quietly confident.

enjoyed reading ur post!congrats on being a father!
and do keep us updated on ur mods!! a video is definately the need of the hour

COngrats for the Princess

and enjoyed the post to its Core ,,looking forward to the Video

ROFL!

Interesting write up! Waiting to hear the whole experience in your words!

BEWARE, this looks painful

The first pic is of my right leg, was roaming around in shorts, why not it's hot and I was local, burnt my lower leg on the FFE, you live and lean, right?

The second is not what some may think it is it's actually a DB killer, if you look closely you can see it's quite restrictive, it reduces around 10% of DB and probably 15-30% in power, once the rest of my kit is installed, I will most likely ride without it. Riding with an Rjays Octane Camo jacket helps to keep the cops at bay, especially as there is Navy and Army bases in my vicinity.

Anyway D-Day is approaching, great thing is that D-Day (the real one) is on my birthday, so I will over use this term, because i can.

Was planning on doing the install today, didn't happen, have a little spare time tomorrow, the mech's busy, all good though, we're scheduled for Sunday! I can tie up my loose ends by then and am good to go! Going to meet the mech tomorrow as I want to make sure we have the oil, filters and gaskets required to do the work and the 2 oil changes.

Going to make a video of the install, not sure I'll be able to mount the cam for the break in though, if I have time will make a preliminary report on D-Day, not sure though as my cousin has just come down from WB, so may not have time and I want a couple of bachelor nights before my wife and daughter come home next week.

I love your Avatar,by the way Follow the same philosophy.

Hey Bro, Would like to meet you and your tigress next time i come down to goa.

Congrates for princess.. Enjoyed your post a lot!!! looking for pics and videos..!!!

Thanks for the comments guys,

D-Day was today, it came a day early, just like the original covert operation.
After a heavy night last night, had met my cousin, who i had not seen in 20 years, so a few drinks flowed and woke up with my head banging on the inside, so after some tea (the original Spice of Life), a shit, shower and shave, I packed my bag and went to the workshop. The mech was extremely busy, I had reached at around 10.45 am, he said he be atleast 90 mins before he could start, no prob I thought, he had the gaskets and oil filters ready, I figured I would finish my work and be back by 12, we'd get the install done by 3pm, so I thought.....

Returned by 12, he was still busy, I didn't want to rush him and I didn't want him to take any tension, so I waited patiently, the junior mech began removing the fairing by 12.45, 1.30 he began removing the engine, by 2.10 the engine was out and ready for surgery, time for lunch.

We resume at 2.40 pm, the engine is disassembled within 30 minutes, more customers start coming in, a couple get turned away, others are pending work which he needs to complete, so a few small delays, no problem though, as I want my work done thoroughly and the mech should be calm, patience is a virtue!

So progress is a little slow around 1 hour gets eaten by other customers, that's cool though, at around 4pm, he realises that he doesn't have the 0.06mm feeler gauge to set the inlet and exhaust valves, so off i go and get him a full set as a gift.

Engine is refitted with the new bore/block and camshaft, it is promptly refitted, the ffe is refitted with a new gasket, timing chain adjusted and the simota airfilter is installed, new mineral oil is filled and a new oil filter installed.

Install is done, the bike is minus her fairings, a bit like mutton dressed as lamb, she's not looking so sexy naked as she does fully clothed and make up. Anyway time to fire her up, she fires up on the first crank, nice, in the mean time I have removed the DB Killer, she roars like a lioness now. Time to take her outside.

Now outside the workshop, I fire her up, a half crank and then a full crank and she roars into life, this is due to the camshaft not having a decompression lever, I let her warm up for around 3-4 minutes.

I had decided long ago, that I would do a hard break in for the big bore, while it's a controversial subject, i didn't want to pussy foot around and baby sit the bike for a month or so, plus the arguments for this technique and perfect logical sense, much more so than those against it, each to their own.

So off I go, I had no real plan to which direction to take, I need to complete around 20 miles or 32 km's, some reason I was thinking 50 kms, I had done 42km's by time i had returned to the workshop.

Now in that 42km's I had gone through all the gears, hit the rev limiter twice, actually I wasn't intending to go above 8.5km, the high lift camshaft makes the rpms fly above 6k rpm, a lot of full throttle acceleration and full on engine breaking was order of the day!

Now the bike is quick, very quick, 100kmph comes up very quick, probably in less than 9 seconds, there is plenty of torque from 3k rpm, the high lift cam comes to life after around 6k rpm, it gives a feeling of a turbo kicking in, just a little more subtle, it gives a great punch though.

Back to the workshop, we drain the oil, lots of metal shavings are present in the 60 minute old oil as expected. We fill up with new mineral oil, new oil filter, bolt the fairings back on, it's now 8.30 pm, I pay my bill to the mech, total of Rs2260, Rs850 of it is labour, the rest is gaskets, oil and oil filters and another Rs200 for the feeler gauge set.

Now, I have done around 55kms since the rebore, right now there are plenty of vibes, compared to stock, guess I'll need some new gloves!
The exhaust without the DB killer is much louder when you're on the bike with someone else riding I couldn't tell much difference to be honest.

^^^ congratulations .... Ride safe & live strong

The big bore has very tight tolerances. More than 2k kms later, my engine was still freeing up noticeably. This can give you an idea about the tolerances. Its best to run it in comfortably. The vibes will be much less after 1k kms. But, it will not be exactly as smooth as stock. And yes, the cam and the db killer does not go together.

Liked reading your review!

^^^ +1, the tolerances are extremely tight... will require at least 3000 kms for the rings to set in well, also by the time the rings set in there will be a increase in the compression... so my two cents... keep an eye out for overheating and piston scuffing, this can happen very very quickly....

One thing I forgot to add yesterday, I didn't really pay it any mind, but today a little paranoia kicked in.

From the first crank after the rebuild, I had noticed a loud ticking sound, this gets louder and faster as the revs climb, it actually can be heard above the exhaust. Now i'm not 100% sure what it is, pretty sure it's not the new bore, 90% ruled out that it's coming from the exhaust outlet as we changed the exhaust gasket. Thinking back during the install, the mech was having trouble fitting the timing chain and got interrupted a few times during this process, this is the most likely cause in my mind, we had set the valve clearances as per Joel's instruction, so that can also be ruled out.

Not wanting to make things worse, I have decided not to use the bike until I can resolve this issue, it may something simple such as we may just need to retard the timing a little, I have emailed Joel for some advice, hopefully I will get a reply soon. The problem now is the mech who done the install is going out of station on Tuesday, I am heading off to Bombay on Wednesday or Thursday, I don't have a great deal of free time either. I am thinking to take the bike to a different mech close by and go for a strip down and check, only thing he is not familiar with the bike, but he's quite thorough and was telling me today he doesn't have much work on, so he'll be at least keen.

Anyone have any pointers to where we should first look at?

^^^ most probably the de-compression lever which is making the ticking sound.... Still will advise you to be careful running in the build as tight tolerances can lead to heat buildup very quickly....