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thirdgen's massive F4i rebuild thread.... pix intense!!
Well... I just uploaded 265 pictures to photobucket, won't be posting every one of them, but just be warned.... this is gonna be a looooong thread with ALOT of pictures!! LOL
Anyways, some may remember I went down back in Dec and the whole ordeal that followed. For those that don't.... back on Dec 17th I was on my way to work and while veering off on a road to the left, I hit a patch of oil/diesel fuel/antifreeze/something slippery, and lowsided at about 25 mph. All was fine until the bike slid into the curb, did a little highside and then rolled over itself into the grass. I got right up, not even so much as a scratch on me, thank god (leathers FTMFW!!), went over to the bike and it was completely covered in engine oil. Not a good sign already! Luckily another guy from work was several cars behind me when this happened, so he saw it and recognized it as being me, and pulled right into the parking lot there and made sure I was OK. Luckily he had his pickup and an empty bed, so we lifted the bike into the bed of his truck and off to work we went http://i2.photobucket.com/albums/y15...s/8d1f7121.jpg http://i2.photobucket.com/albums/y15...s/eafd5308.jpg He gave me a ride home after work and we unloaded the bike into the garage. I was able to get a little better analysis of the damages http://i2.photobucket.com/albums/y15...s/DSC01578.jpg http://i2.photobucket.com/albums/y15...s/DSC01559.jpg http://i2.photobucket.com/albums/y15...s/DSC01560.jpg Right side didn't really get much at all http://i2.photobucket.com/albums/y15...s/DSC01561.jpg http://i2.photobucket.com/albums/y15...s/DSC01562.jpg Swingarm got gouged up pretty good http://i2.photobucket.com/albums/y15...s/DSC01564.jpg http://i2.photobucket.com/albums/y15...s/DSC01565.jpg Now for the really bad part.... when it slid, the flywheel took a hard and direct hit with the curb http://i2.photobucket.com/albums/y15...s/DSC01566.jpg http://i2.photobucket.com/albums/y15...s/DSC01567.jpg Took a good size chunk out of the lower crankcase http://i2.photobucket.com/albums/y15...s/DSC01570.jpg http://i2.photobucket.com/albums/y15...s/DSC01573.jpg All that was left of my stator cover http://i2.photobucket.com/albums/y15...s/DSC01574.jpg Definitely not a good sign there! http://i2.photobucket.com/albums/y15...s/DSC01580.jpg A couple weeks later, after much persuasion with a pry bar I was able to get the mangled stator out of the flywheel. Thanks to a generous member of 600rr.net for loaning me the OEM flywheel puller tool, I was finally able to remove the flywheel and inspect behind it. I was quite sad with what I found Crank was definitely bent http://i2.photobucket.com/albums/y15...Picture063.jpg The crack in the case was also worse that I had originally seen http://i2.photobucket.com/albums/y15...Picture033.jpg Several weeks went by waiting for the insurance adjuster to come out to the house and look at it. I already knew they were gonna total it, but it was pretty much my only option at this point. They finally came out and looked at it, then had to wait another couple of weeks for them to process everything. Contrary to everyone else telling me "don't bother, it's not worth anything anyways", I'm glad I didn't listen, cuz the insurance company thought otherwise. They valued the bike at $4400, subtract $500 deductible and we're at $3900.... then the buy back was $600, and I went ahead and did just that. So I kept the bike, and got a check for $3300. For a bike with 177k miles on it, can't really complain at all I was in the process of moving at the time, so I didn't really have much of any time to work on it, plus I didn't want to tear it apart before I moved, then end up having to move it in pieces and loosing stuff. I moved the bike over to my new residence and it sat there for another couple of weeks. My buddy Matt's boss down in Greenville, SC is an engineer with a full machine shop, CNC machines, welders, lathes, etc. He said he might be able to fix it, so he said bring it on down and we'll tear it open and have a look Finally by the end of Feb, I was settled into my new place and had some time to work on the bike. I quickly got to work tearing it down http://i2.photobucket.com/albums/y15...s/09f433d8.jpg http://i2.photobucket.com/albums/y15...s/d23c5eec.jpg Rafters and ratchet straps are a godsend!! http://i2.photobucket.com/albums/y15...s/ec60559e.jpg |
And milk crates too, hahah
http://i2.photobucket.com/albums/y15...s/4e3b4d6c.jpg Had the engine out shortly after http://i2.photobucket.com/albums/y15...s/04977c8b.jpg After 177k miles, she's a little dirty, as one might imagine http://i2.photobucket.com/albums/y15...s/1ccd3ff4.jpg http://i2.photobucket.com/albums/y15...Picture013.jpg http://i2.photobucket.com/albums/y15...Picture035.jpg http://i2.photobucket.com/albums/y15...Picture001.jpg Wasn't much left of her after that http://i2.photobucket.com/albums/y15...s/92bb161b.jpg http://i2.photobucket.com/albums/y15...Picture051.jpg Oh and around this time, I came across this little gem on ebay so I picked it up for a steal ($300 for both). I asked the guys in the body shop at my work if they could paint it up and fix a small crack, and they said sure, so I dropped it off ever there. Also took my tail section which had a few scratches and cracks, and a few other goodies I bought as well (you'll see those at the end) http://i2.photobucket.com/albums/y15...Picture016.jpg So in March our schedules finally work out and I take it down to Greenville, SC and have my buddies boss take a look. We start tearing the engine open. Nothing has been cleaned in these pics, it's exactly as we tore it apart http://i2.photobucket.com/albums/y15...2/DSC01636.jpg http://i2.photobucket.com/albums/y15...2/DSC01637.jpg Remove the cyl head (first time ever been off).... pistons have a little carbon buildup, but nothing major http://i2.photobucket.com/albums/y15...2/DSC01640.jpg http://i2.photobucket.com/albums/y15...2/DSC01641.jpg Flip it upside down and remove the oil pan so we can split the cases http://i2.photobucket.com/albums/y15...2/DSC01643.jpg Engine is spotless inside http://i2.photobucket.com/albums/y15...2/DSC01644.jpg http://i2.photobucket.com/albums/y15...2/DSC01645.jpg Lower crankcase removed http://i2.photobucket.com/albums/y15...2/DSC01646.jpg Crank journals and bearings still looked brand new http://i2.photobucket.com/albums/y15...2/DSC01647.jpg http://i2.photobucket.com/albums/y15...2/DSC01648.jpg We pull the crankshaft out, and sure enough, just as we thought. Bent beyond any conceivable repair http://i2.photobucket.com/albums/y15...i/cb076557.jpg |
The case was severely cracked under the end crank journal bearing
http://i2.photobucket.com/albums/y15...i/3ba04810.jpg So.... I wasn't too happy at this point. This was the last little bit of hope I was hanging onto to possibly fix my original engine. But, not gonna happen. I gave it some thought, and pretty much my only option at this point was another engine. The timing could not have been better, as I quickly went on ebay and found a 2004 F4i engine with 15,000 miles. It was at $200 with no reserve, only catch was he wouldn't ship it, pick up only in Atlanta, GA. I watched the auction like a hawk, nobody was bidding on it for several days so I thought I was in the clear. I sit there and watch it in the final several minutes, and lets just say I won the auction in a furious snipe at about 5 sec remaining, outbidding someone else who had the same idea, hahaha. Ended up getting it for $256.... hell of a deal! So that weekend I hop in the trusty Accord and make my way down to Atlanta, GA from Asheville, NC http://i2.photobucket.com/albums/y15...2/DSC01675.jpg http://i2.photobucket.com/albums/y15...2/DSC01677.jpg Getting closer! http://i2.photobucket.com/albums/y15...2/DSC01678.jpg As I'm approaching Atlanta, I tighten my seatbelt and say a little prayer for my life as I merge onto, what I always appropriately like to call, the "I-285 GP". Wow..... I was quickly reminded just why I hate driving in Atlanta....ever!! http://i2.photobucket.com/albums/y15...2/DSC01681.jpg I make my way into the city, where I'd meet up with a guy named Sean. We met up at the Cycle Gear since we both knew right where it was http://i2.photobucket.com/albums/y15...2/DSC01683.jpg Picked up the engine and stuffed it in my trunk, right next to my old engine http://i2.photobucket.com/albums/y15...Picture030.jpg Went over to my buddy Kevin's house north of Atlanta where I'd crash for the night. We took the new engine out and did a valve check on it just to see where it was at, and how it looked http://i2.photobucket.com/albums/y15...2/DSC01684.jpg Had 2 valves that were slightly out of spec. One was loose, one was tight, so we were able to swap shims and got both in spec. Everything else looked pretty good, and clean http://i2.photobucket.com/albums/y15...2/DSC01685.jpg http://i2.photobucket.com/albums/y15...2/DSC01688.jpg The next night I make my way back home to Asheville, NC, driving through some of the worst rain I've driven through in YEARS, might I add, lol. On the nice 5 hour drive home I gave the whole situation lots of thought. Me being the stubborn SOB that I am, still wasn't truly happy with just replacing the engine. I kept thinking...there's GOTTA be a way to keep at least part of it original. Then... DUH.... *lightbulb* So I took the new engine into work the next morning http://i2.photobucket.com/albums/y15...2/DSC01689.jpg http://i2.photobucket.com/albums/y15...2/DSC01690.jpg http://i2.photobucket.com/albums/y15...2/DSC01691.jpg I needed to take the clutch out anyways to swap my Factory Pro shift star and detent spring I had put in mine awhile back http://i2.photobucket.com/albums/y15...2/DSC01705.jpg Got the clutch out, and wasn't too happy with what I saw. Had some pretty good bluing and burn marks on the clutch plates, as well as some pretty deep grooves in the ears on the inner and outer clutch baskets. RED FLAG!! http://i2.photobucket.com/albums/y15...2/DSC01707.jpg Now that my suspicions are raised, I keep digging a little further. By now my decision was pretty much made up as to just what I was gonna do http://i2.photobucket.com/albums/y15...2/DSC01712.jpg http://i2.photobucket.com/albums/y15...2/DSC01703.jpg http://i2.photobucket.com/albums/y15...2/DSC01704.jpg http://i2.photobucket.com/albums/y15...2/DSC01710.jpg About the same amount of carbon buildup on the pistons as mine had.... not too bad http://i2.photobucket.com/albums/y15...2/DSC01713.jpg |
Bent crank
http://i2.photobucket.com/albums/y15...2/DSC01663.jpg It bent so much that it actually squished and buckled the metal on the one side... http://i2.photobucket.com/albums/y15...2/DSC01666.jpg ...And stretched it on the other side http://i2.photobucket.com/albums/y15...2/DSC01668.jpg As for the crank journals themselves... perfect http://i2.photobucket.com/albums/y15...2/DSC01669.jpg http://i2.photobucket.com/albums/y15...2/DSC01672.jpg http://i2.photobucket.com/albums/y15...2/DSC01674.jpg http://i2.photobucket.com/albums/y15...2/DSC01670.jpg Time to start assembling the "new" engine. I hone out the cylinders real good on the new block to deglaze them http://i2.photobucket.com/albums/y15...2/DSC01735.jpg Now here's another little interesting tidbit. I start measuring ring gap, and I'm curious how my 177k mile engine compares to this 15k mile engine (which I now believe was run a bit hard). The service limit on the upper ring is 0.40mm. So using cylinder 1 in the new block, I take the upper ring from both cylinder 1 pistons of the new engine and my old engine. The ring from the new engine is right at the 0.40mm service limit. My 177k mile ring measured 0.27mm. Yea..... figure that one out! http://i2.photobucket.com/albums/y15...2/DSC01781.jpg Used a brass scraper to clean the surface of the block up http://i2.photobucket.com/albums/y15...2/DSC01784.jpg After cleaning the carbon off the pistons and making sure the ring grooves are nice and clean, gotta index the rings before reinstalling each piston (each ring gap has to be facing a certain way) http://i2.photobucket.com/albums/y15...2/DSC01788.jpg Install each piston http://i2.photobucket.com/albums/y15...2/DSC01785.jpg Use lots of this stuff!! http://i2.photobucket.com/albums/y15...2/DSC01792.jpg My original rod bearings.... perfect http://i2.photobucket.com/albums/y15...2/DSC01789.jpg http://i2.photobucket.com/albums/y15...2/DSC01790.jpg After several gradual steps, make my way to 19 lb.ft on the rod caps http://i2.photobucket.com/albums/y15...2/DSC01794.jpg Hard to see in the pics, but the lighter color timing chain guide on the left has more wear than the one on the right. One on the left is out of the 15k mile engine, one on the right is my original. I put my original back in http://i2.photobucket.com/albums/y15...2/DSC01796.jpg Finally installed the new timing chain that I've had sitting in my toolbox since.... 2005?? LOL http://i2.photobucket.com/albums/y15...2/DSC01798.jpg http://i2.photobucket.com/albums/y15...2/DSC01799.jpg Used my original oil pump http://i2.photobucket.com/albums/y15...2/DSC01801.jpg |
Installed oil pump and my Factory Pro roller bearing detent spring
http://i2.photobucket.com/albums/y15...2/DSC01804.jpg Installed my original shift drum with the Factory Pro shift star http://i2.photobucket.com/albums/y15...2/DSC01809.jpg http://i2.photobucket.com/albums/y15...2/DSC01814.jpg My shift forks were still in perfect shape, so reused those too http://i2.photobucket.com/albums/y15...2/DSC01811.jpg http://i2.photobucket.com/albums/y15...2/DSC01815.jpg Can't forget the oil control orifices! That would be a very bad thing to leave out http://i2.photobucket.com/albums/y15...2/DSC01817.jpg Bottom end... complete! http://i2.photobucket.com/albums/y15...2/DSC01819.jpg After applying some assembly lube on all the crank bearings, install the lower crankcase http://i2.photobucket.com/albums/y15...2/DSC01820.jpg Torque all case bolts down to spec http://i2.photobucket.com/albums/y15...2/DSC01824.jpg http://i2.photobucket.com/albums/y15...2/DSC01826.jpg Install oil pick-up and pressure release valve http://i2.photobucket.com/albums/y15...2/DSC01828.jpg Oil pan http://i2.photobucket.com/albums/y15...2/DSC01829.jpg Flip over and install oil cooler http://i2.photobucket.com/albums/y15...2/DSC01830.jpg http://i2.photobucket.com/albums/y15...2/DSC01831.jpg Install shift shaft http://i2.photobucket.com/albums/y15...2/DSC01833.jpg Oil pump drive chain and sprockets http://i2.photobucket.com/albums/y15...2/DSC01834.jpg Install the outer clutch basket http://i2.photobucket.com/albums/y15...2/DSC01835.jpg Then the inner hub, then tighten the nut (94 lb. ft = FUN when the engine is out, lol) http://i2.photobucket.com/albums/y15...2/DSC01836.jpg My original (yes 177k mile original) clutch was still in great shape, so I reused it http://i2.photobucket.com/albums/y15...2/DSC01837.jpg Coat all the clutch friction and steel plates with clean engine oil before install http://i2.photobucket.com/albums/y15...2/DSC01839.jpg |
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Install clutch pressure plate and springs, tighten to 9 lb.ft http://i2.photobucket.com/albums/y15...2/DSC01843.jpg Time to button up the top end http://i2.photobucket.com/albums/y15...2/DSC01856.jpg http://i2.photobucket.com/albums/y15...2/DSC01857.jpg Cleaned the carbon off my original head and it cleaned up nicely http://i2.photobucket.com/albums/y15...2/DSC01858.jpg http://i2.photobucket.com/albums/y15...2/DSC01860.jpg Easy does it when it comes to torquing a head. Lots of small increments is my preferred method http://i2.photobucket.com/albums/y15...2/DSC01864.jpg Final torque of 35 lb. ft (much better than the 245 lb. ft for the ARP head studs I usually do on the diesels, lol) http://i2.photobucket.com/albums/y15...2/DSC01865.jpg Install exhaust camshaft and line up timing marks http://i2.photobucket.com/albums/y15...2/DSC01866.jpg http://i2.photobucket.com/albums/y15...2/DSC01867.jpg Install intake camshaft and line up timing marks http://i2.photobucket.com/albums/y15...2/DSC01868.jpg http://i2.photobucket.com/albums/y15...2/DSC01869.jpg Gotta torque the cam hold down plate in the EXACT sequence numbered on the plate http://i2.photobucket.com/albums/y15...2/DSC01871.jpg http://i2.photobucket.com/albums/y15...2/DSC01872.jpg Rotate the engine slowly by hand to make sure no problems, then recheck timing to make sure it's dead on http://i2.photobucket.com/albums/y15...2/DSC01874.jpg And at the crank too http://i2.photobucket.com/albums/y15...2/DSC01875.jpg Looking like an engine again! http://i2.photobucket.com/albums/y15...Picture024.jpg http://i2.photobucket.com/albums/y15...Picture025.jpg Do a quick compression test just to make sure no major problems. Not perfect, but for an engine that is cold (supposed to do it warm) and hasn't run yet, that's still pretty damn good http://i2.photobucket.com/albums/y15...2/DSC01877.jpg Install spark plugs http://i2.photobucket.com/albums/y15...2/DSC01880.jpg |
Reused my original water pump
http://i2.photobucket.com/albums/y15...2/DSC01881.jpg The stator cover that came on the new engine had some rash, so I sanded it down to remove the scratches http://i2.photobucket.com/albums/y15...Picture060.jpg Then just painted it flat black with some hi-temp paint http://i2.photobucket.com/albums/y15...2/DSC01852.jpg Install the stator back in the cover http://i2.photobucket.com/albums/y15...Picture028.jpg Install the stator and cover, valve cover, and thermostat housing and hoses, and she's complete, ready to go back in! http://i2.photobucket.com/albums/y15...2/DSC01882.jpg http://i2.photobucket.com/albums/y15...2/DSC01884.jpg http://i2.photobucket.com/albums/y15...2/DSC01889.jpg So I hung the ratchet straps from the rafters once again, and wheeled the bike into position http://i2.photobucket.com/albums/y15...2/DSC01891.jpg http://i2.photobucket.com/albums/y15...2/DSC01891.jpg Get the engine into position http://i2.photobucket.com/albums/y15...2/DSC01893.jpg Slowly lower the frame down onto the engine http://i2.photobucket.com/albums/y15...2/DSC01894.jpg Annnnd.... she's in! http://i2.photobucket.com/albums/y15...2/DSC01895.jpg http://i2.photobucket.com/albums/y15...2/DSC01896.jpg Gotta tighten the engine mount bolts in a certain sequence to center the engine, then use the special tool to tighten the adjuster lock nuts on the right side http://i2.photobucket.com/albums/y15...2/DSC01915.jpg Install the radiator http://i2.photobucket.com/albums/y15...2/DSC01899.jpg Tighten all coolant hose clamps http://i2.photobucket.com/albums/y15...2/DSC01901.jpg Attach clutch cable http://i2.photobucket.com/albums/y15...2/DSC01904.jpg Fill it up with quality cooling juices http://i2.photobucket.com/albums/y15...2/DSC01910.jpg Never forget the lube http://i2.photobucket.com/albums/y15...2/DSC01903.jpg Double check level.... it takes a little more oil after a major surgery http://i2.photobucket.com/albums/y15...2/DSC01909.jpg |
By this point, the anticipation was absolutely KILLING me!! For the past 4 months, all I wanted to do was hear her run again. Cosmetics or anything else I wasn't worried about, I just wanted to hear her run. So I stopped there, made sure I had everything connected engine wise, bolted the exhaust on, and stuck the gas tank on. Had a gas can with a little bit of gas in it so I poured a little bit in the tank. I was just saying a prayer.... pleeeeeease start up, please start up! There were so many things running through my mind... "did I tighten that?".... "Did I remember to put that piece in?".... "Did I leave anything loose?"..... "I did put oil in right?"..... "What if it doesn't start?". Seriously all the "what if's" running through my mind at 100 mph. But, I connect the battery and all the lights come on and the fuel pump primes. I switch it off and on several times to fill up the lines with fuel. I had my fingers crossed and made this video..... it is indeed the very first attempt to start it. Watch and see!
YouTube - MOV01897.MPG WoooooooooHooooooo!! Success!! Seriously, words can't describe how happy I was to hear her start right up and run.... perfectly. Both a huge sigh of relief, as well as a huge feeling of accomplishment, I was almost crying happy tears just to hear her run again, and something I assembled piece by piece with my own two hands. It's a feeling like no other! So.... after she was running like a champ, I moved on to other stuff. Remember the swingarm that was all rashed up?? http://i2.photobucket.com/albums/y15...Picture019.jpg http://i2.photobucket.com/albums/y15...Picture059.jpg I sanded it down with my whiz wheel (same as the stator cover). It slowly shaves the metal down and removes the scratches little by little until they're gone http://i2.photobucket.com/albums/y15...Picture067.jpg I then used some Mothers metal polish and an orbital buffer to smooth it down to a nice shine http://i2.photobucket.com/albums/y15...Picture069.jpg I then used course steel wool and hand sanded for about 3 hours, slowly removing any little scratches from the sanding, and giving it that brushed aluminum finish that was on it originally http://i2.photobucket.com/albums/y15...Picture018.jpg It turned out pretty damn good if I do say so myself! http://i2.photobucket.com/albums/y15...Picture049.jpg There's still a small bit of rash at the very bottom.... it was too deep I'd have to sand too much. It's alot better than it was though http://i2.photobucket.com/albums/y15...Picture062.jpg Apply several coats of commercial grade clear coat to protect the metal http://i2.photobucket.com/albums/y15...2/DSC01913.jpg Install the swingarm on the bike http://i2.photobucket.com/albums/y15...2/DSC01916.jpg Hey sometimes you gotta get creative when you don't have a big enough hex bit, haha http://i2.photobucket.com/albums/y15...2/DSC01917.jpg Hey whatever works, right?? http://i2.photobucket.com/albums/y15...2/DSC01920.jpg After centering the swingarm, use the special tool to tighten the adjuster lock nuts http://i2.photobucket.com/albums/y15...2/DSC01921.jpg http://i2.photobucket.com/albums/y15...2/DSC01922.jpg And of course the pivot bolt http://i2.photobucket.com/albums/y15...2/DSC01923.jpg Install rear wheel and rear brake caliper http://i2.photobucket.com/albums/y15...2/DSC01924.jpg OMG... starting to look like a bike again! http://i2.photobucket.com/albums/y15...Picture003.jpg My fairing stay was tweaked just a little bit, mostly on the left side http://i2.photobucket.com/albums/y15...2/DSC01925.jpg http://i2.photobucket.com/albums/y15...2/DSC01928.jpg So I replaced that too http://i2.photobucket.com/albums/y15...2/DSC01929.jpg Now.... my plastics!! I got them back from the body shop, and they turned out fantastic! They repaired the small crack in the upper fairing, fixed some rash and cracks in the tail fairing, and fixed a big rock chip in the hugger, then painted them all black. The headlight had a tiny scratch so he sanded that down and got it nice and clear again. Solo seat cowl was red prior, they painted that black too. All of this cost me.... nothing. I tried to pay them, they don't take it, not even for paint. Good thing for having buddies in the body shop who are also riders themselves, huh?? LOL http://i2.photobucket.com/albums/y15...2/DSC01930.jpg |
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Got my HID bulbs and Proton flushies transferred over to the new headlight http://i2.photobucket.com/albums/y15...2/DSC01933.jpg Front and side fairings installed http://i2.photobucket.com/albums/y15...2/DSC01934.jpg Tail installed http://i2.photobucket.com/albums/y15...2/DSC01935.jpg http://i2.photobucket.com/albums/y15...2/DSC01936.jpg http://i2.photobucket.com/albums/y15...2/DSC01937.jpg http://i2.photobucket.com/albums/y15...2/DSC01938.jpg Well... she's back together!! Only things I was missing here were my Puig DB windscreen and the left side fairing. Waiting for both of them to arrive in the mail, but damn it I wanted to go ride! Still had my stock windscreen so I put that on, and everything was tight enough without the left side fairing, so screw it, lol. So... Sat April 3rd around 5pm or so, letting her warm up, about to go take our maiden voyage! http://i2.photobucket.com/albums/y15...2/DSC01939.jpg Rode around town staying close to home just to be safe, incase anything went wrong. Everything was perfect though.... temp was staying where it should, plenty of power, everything was smooth and crisp, no vibrations... nothing. So I get on the highway for a short bit...all good there! Make my way up to the Blue Ridge Parkway. Made a quick video just to show how good she's running. Ended up logging 110 miles before the night was over YouTube - MOV01943.MPG Several days later my windscreen and left fairing show up in the mail http://i2.photobucket.com/albums/y15...Picture037.jpg I've always been one for a clean stock look, so I put the decals back on (still waiting on the ones for the front upper... they were on backorder) http://i2.photobucket.com/albums/y15...Picture002.jpg http://i2.photobucket.com/albums/y15...Picture023.jpg So today I had everything all done and got her all cleaned up. I took her up to that special place up on the BRP for some quality pix. Here's the ending result of my past 4 months of work http://i2.photobucket.com/albums/y15...2/DSC01945.jpg http://i2.photobucket.com/albums/y15...2/DSC01946.jpg http://i2.photobucket.com/albums/y15...2/DSC01947.jpg http://i2.photobucket.com/albums/y15...2/DSC01948.jpg http://i2.photobucket.com/albums/y15...2/DSC01949.jpg http://i2.photobucket.com/albums/y15...2/DSC01950.jpg I still need to get a 'new' left side fairing... this was just a cheapo ebay one to cover it up for now. Couldn't spend the $400 right now, ugh http://i2.photobucket.com/albums/y15...2/DSC01960.jpg I'm damn proud of how well the swingarm came out, hahah http://i2.photobucket.com/albums/y15...2/DSC01952.jpg |
New rear hugger.... been wanting one of these forever
http://i2.photobucket.com/albums/y15...2/DSC01953.jpg http://i2.photobucket.com/albums/y15...2/DSC01954.jpg http://i2.photobucket.com/albums/y15...2/DSC01955.jpg http://i2.photobucket.com/albums/y15...2/DSC01956.jpg http://i2.photobucket.com/albums/y15...2/DSC01964.jpg http://i2.photobucket.com/albums/y15...2/DSC01980.jpg The wreck happened at exactly 177,428 miles..... been riding her for about 5.5 days now and logged exactly 951 miles. Still running absolutely perfect, and haven't had a single problem! First full tank of fuel I burned through I got 42.87 MPG, so I would venture to say she's running pretty good! http://i2.photobucket.com/albums/y15...2/DSC01985.jpg And last but not least..... one INCREDIBLY happy thirdgenlxi http://i2.photobucket.com/albums/y15...2/DSC01967.jpg Phew.... that's all the pics! Thank god, I've been typing this for about 5 hours now, and really getting a headache, lol. But yea, everything ended up working out in the end, and I'm just happy to have my baby back, and still running on about 95% of her original engine. I swapped EVERYTHING from my old engine to the new block, everything down to the neutral indicator switch, oil pressure sensor, and thermostat housing. Only parts used from the new engine were the block, crank and crank bearings, and starter (mine started giving probs after I took it out). Every other part in or on the engine.... original. It may not be 100% anymore like it was, but hey, given the situation I think it's the best solution I had to keep her as original as I possibly could. And it worked! And for all the people that kept telling me it wasn't worth it, and it was gonna cost more to fix it than it would be to buy a new bike, hear this: Grand total for EVERYTHING I did was right at $1100. I used the remaining $2200 to pay off a $2200 credit card debt that's been hanging over my head for waaaayyyy too long now, so it's completely gone. So now I have MY bike back, and no debt at all.... I think I like my way of handling this situation a little better than alot of the responses I got, lol. Plus I've got a box full of engine parts to sell, maybe make a few bucks back! Anyways, hope you all enjoyed the pics! Sorry if I made your computer crash. Roadtrip pics will be soon to follow! |
Dude..that is fucking AMAZING.
Fantastic work..and very impressive!! |
Looks great!
I can't believe how good the internals looked from that 177k motor - you really are a freakin' machine, dude. I wonder how the internal parts of your 400k car look? I'm wagering they look about the same as the insides of your F4i. Freakin' awesome. I was hoping you'd just replace the broken bits and leave the rest as-is http://www.twowheelfix.com/showpost....23&postcount=9 I know when my car got totaled at 210,000 I wanted to keep everything I could (alas, I was broke and couldn't keep the car). I totally understand wanting to keep something as original as possible when it's served you so well. |
Pretty sure it took me an hour to get through this thread, but damn. Nice work man. Really nice. Impressive that your engine was in better shape than the new one. Really speaks volumes to your maintenence.
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Excellent! I'm still putting my 748 together after buying it with a spun crank. I didn't take anywhere near that many pictures! LOL But, I am taking video of the whole thing.
I've had to take a couple of bikes down that far, and it is very rewarding when you hit the starter button and it actually starts! Congrats! Looks great! |
That was a hell of a project. Nice work. I'm amazed at the condition of the engine internals. I hope you get another 177k out of it.
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Dang man. You did all that hard work just to get bug juice on your new bike. I thought you were a clean guy.
Congrats man. I know the feeling about keeping something you love alive. Feels good. Got a couple questions if you dont mind answering. 1. Does it have a salvage title now and does your insurance company insure salvage? I've always looked at salvage deals but never really got to the point of cash in my hands. 2. What oil have you been running for the most miles on your bike? I see that you're using a puralator 1 filter. I do to. Wish I could fit a big one on my engine like you can on yours. I have rad hoses in front of mine so I have to use the 3.5" height ones. |
Was wondering the same thing about the title.
So yeh what kind of magic joojoo juice do you use to keep the engine that good looking? |
Its crazy how his 177k mile engine had the same amount (or less) carbon build up as the 15k engine.
This is why I hate buying used. |
Looks great man. Glad you got it done and happy.
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BRAV -F_ _ _ _ _ _ - O!!!!!!!!!!!! great job, and on to 200k mi. |
Awesome work, pics and thread!
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Awesome work Jared!
I'm sure she'll treat ya right for thousands of miles yet. Did you even use the old spark plugs? looked like it in the pic :lol: |
Amazing.... you should foreward this story along to American Honda.
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Very glad you got it back together and it's running great. |
Dude, You are an inspiration to everyone out there in the world who wants to aspire to do shit but is afraid of the consequence...Holy fuck, That was an AWESOME read!!!!
I gotta make it down to NC one of these days and catch a ride with you man, Your fucking crazy...I love it. |
Awesome
Fucking Thread This should be a sticky |
Whew, now I don't have to keep this a secret anymore! :lol
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That's insane. Really fcking insane. I'm happy for you man. It's cool you that were able to keep some of the original engine. Also, nice pics and story/explanations. I had fun following along.
I didn't look at the time before I started scrolling through, but I'm sure it took me about an hour as well. |
Great job Jared! I'm glad the infamous F4i is back on the road.
The best part of this entire re-build was that you did it at work (or at least that is what I understood). :lol: |
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As for oil.... well when the bike was brand new I broke it in using the regular Honda dino oil that came with it (changed several times, of course). Then at 5,000 miles I switched to Mobil 1 full syn 15w-50, then a couple years later 10w-40 when it came out (wasn't available at first). Yes... car oil! The same stuff everybody says will make your engine blow up and your clutch slip if you use it, lol. That's half the reason I posted this up was just to shut a few people up on the whole oil and mileage debates, lol. Been using the Mobil 1 ever since then, changed like clockwork every 5000 miles. Never had a single problem! Quote:
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I'm hoping to make it to the rally this year, so if you're gonna make it this year I may just meet you then. I probably won't be able to stay the whole time, but should be able to stay a day or two at least and meet you guys! Quote:
Anyways, thanks guys soooo much for all the compliments and kind words!! Really glad you enjoyed the pics and story!! Makes me feel good knowing I'm not the only one that appreciates all the hard work that went into this project. I've now logged just over 2,000 miles on her since I got her up and running again, and have not had a single problem! I changed the oil once already after the first 600 miles (it was getting a little funky from washing out all the assembly lube, which was black). Put some more Rotella in again and been keeping an eye on it, and it's staying perfectly clean, but gonna change it at 180k and go back to the Mobil 1, and get back on my normal oil change schedule. Not burning or leaking a drop of oil! Or any fluid for that matter, lol. I rode her down to the track at Road Atlanta in Braselton, Georgia over the weekend to watch the AMA Superbike races (awesome!!), and she did great! http://i2.photobucket.com/albums/y15...a/DSC02027.jpg |
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Absolutely amazing man. All of us here at TWFIX give you a grand round of applause. Im going to switch over to the Mobil1 10w40 now lol. I wish i knew half about engines and the workings of a motor as you do. The most ive done is Change oil and Brake pads. I belive this does deserve The Best post Award
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Awesome write up man and good for you...
But the only thing I could think of through all that was... "He isn't going to reuse the rings right?" "He can't be reusing those rings!" "My god I think he reused those rings..." :lol: There also wasnt a step where you Plasti-gauged the Crank Bearings. I just hope that doesnt come back to bite you man. Keep her upright and keep racking up the miles:dthumb: |
Well guys, just figured I'd post a little update on how she's doing. Not all too much to say other than.... bike is running great!!
http://i2.photobucket.com/albums/y15...i/6cd5cc9c.jpg Just went out and snapped this a few mins ago... logged exactly 15,316 miles since April 3rd when I got her running again after the wreck (177,428). In that time she's taken me all throughout North Carolina, South Carolina, Tennessee, Georgia, Virginia, and Maryland without even so much as a hiccup, and still going strong as ever and ridden each and every day. She did the 120 mile/day commute thing every single day (M-F) for 2 months straight without even batting an eye (errr headlight) Only issue I've had was a couple weeks ago, I was over in Hickory, NC on my way to Best Buy, sitting at a long stop light and noticed I hadn't heard my cooling fan come on. Look down at the temp and it's at 231... 235... 239... uh oh! Quickly pull into a parking lot and discover my cooling fan blade is broken right in the center where it attaches to the motor shaft, so the motor is spinning but not the blade... arg! I just replaced this blade about a year ago for breaking in the exact same spot. I just put my old one back on for now that I fixed with some JB Weld and it's working fine for now... gotta go order another one tomorrow. That's the only thing though... everything else motor/trans related is perfect! That's about it... 7,256 until the big 200k mark, shouldn't be too long. I think she'll make it there just fine.... :) |
Jared, why don't you get one made up of a alum?
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I would think a decent metal shop could do it. Use the old one for a template. I'm sure it would be pricey but hopefully you wouldn't have the problems anymore.
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I would as it would easily rip open your rad if it came into contact. You also have to hik about balancing.
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There is a company out there that makes aluminum fan blades for hondas, just gotta google it
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