[BumbleBee1]

So, I thought I would start a thread about my winter project. Picked up a dead 2005 rr from a co-workers husband that got it from a friend, that found it in a grandma's garage that said G'ma road raced back in,,,,, anyways,,, it came from somewhere, and now I HAVE IT!! I hauled it home (most of it in boxes) and started piecing it back together to see if I had everything.

I cleaned up the plastic a little and set the tank back on just to get a better pic of what I had. Figured I should start taking pics of my progress. This thing has not ran since 2013 so I'm sure there will be some issues.

Got a chance today to dig a little deeper into this rig. Haven't found anything horrible yet. Replaced some small tubing that a mouse had chewed off and pulled the spark plugs. I drained the oil, put a new filter on and re-filed with some oil that I will only leave in long enough to run during the diagnosis "period". I hope to get it fired up tomorrow and get enough heat in her so I can locate the coolant leaks and hopefully do a compression check. Anyone know the compression numbers for this bike? Lots of work to do!!!

 

[RJ2112]

Hopefully you will turn it over by hand before using the starter motor….. hard to tell what may have filled the cylinders over the years. If mice chewed the rubber they have been in the air box and exhaust as well. At least two cylinders will have had open valves and rodents love armored housing.

 

[BumbleBee1]

Hopefully you will turn it over by hand before using the starter motor….. hard to tell what may have filled the cylinders over the years. If mice chewed the rubber they have been in the air box and exhaust as well. At least two cylinders will have had open valves and rodents love armored housing.

When I had the plugs out, I scoped the cylinders and pistons. They are all clear. Airbox is good, and I will check the exhaust also. Thanks for the recommendations!

 

[RJ2112]

If you have the plugs out, a compression check would be a good idea.

 

[mmattockx]

Welcome new guy. You're off to a great start with pictures and a build thread. We like pictures here...

Since you're working through a basket case, download a service manual here: Master Service Manual Thread

It should have answers to your question about compression test numbers.


Mark

 

[BumbleBee1]

Welcome new guy. You're off to a great start with pictures and a build thread. We like pictures here...

Since you're working through a basket case, download a service manual here: Master Service Manual Thread

It should have answers to your question about compression test numbers.


Mark

Very nice! Thank you for the link!

 

[BumbleBee1]

Well, she is ALIVE again! Got a chance to mess around with it for a little while today, and she fired right up!! Didn't run it more than 20 seconds or so because I didn't have enough time to do the compression check or chase down coolant leaks. Just happy it started up and sounded pretty good.

Looking at ordering some brake parts. Anyone have a beef with Galfer brake parts?

 

[mmattockx]

Looking at ordering some brake parts. Anyone have a beef with Galfer brake parts?

I had Galfer stainless lines and pads on a K6 GSXR1000. Quality and fitment were good and I had no complaints with either.


Mark

 

[Brevillance]

I've always ran Core Moto stuff but I've heard nothing but good stuff about galfer. I like CM because of all the different color options for custom lines

 

[RJ2112]

Galfer HH pads, Goodrich lines, Woodcraft risers, bars, offsets, bar end sliders, Sato engine sliders, zero gravity screen, different shifter with folding tip, 1” lower pegs using OEM mounts…Penske rear shock. Anything else is almost certainly OEM replacement parts.

 

[BumbleBee1]

Does anyone know what this gasket/o-ring goes to?? I found it laying on the engine case right beside the starter. I know I have seen this before but can't place it. Sorry about the beer can tab,,, it was the only thing I could find for size reference...

 

[Scorpi0]

Isnt it for the little flip thingie on the gas cap?

 

[BumbleBee1]

I figured it out. It's the gasket for the thermostat.. Maybe it was the old one when someone replaced it. I will check it tonight.

 

[mmattockx]

Sorry about the beer can tab,,, it was the only thing I could find for size reference...

Don't worry, you're among friends. We won't judge too harshly unless it's from really cheap beer...


Mark

 

[BumbleBee1]

Well, I think my winter project just got a little more in-depth. I finally got a chance to warm up the bike and do a compression check...

1- 210 psi
2 - 205 psi
3 - 175 psi
4 - 205 psi

Number 3 cylinder has an issue. I guess the engine comes out now and I do a complete tear down. It might just be a blown head gasket, but who knows. The problem is not fixing it, but, I know how I am, and if I tear it down that far I will do more than needs to be done. Maintenance bore, pistons, racing head gasket, head work, ect.... Geez....

 

[BumbleBee1]

Well, finally found some time to play again and found this...

Two broken valve spring retainers. And 2 pretty beat up springs. Is this common on this motor? Here are the pieces that came out.

 

[BumbleBee1]

I got parts in and got a chance to work on this a little more. I can't seem to get the timing right. I have timed many bikes in the past, but this one has me scratching my head. The manual clearly shows the cylinder head surface splitting a cam chain link, but when I pull the front of the chain tight, a full link lines up with the surface. This messes up the pin count and has me wondering about my mental wellness... Any thoughts??

 

[BumbleBee1]

Anyone have any direction on this. I'm at a loss right now.

 

[RJ2112]

If you’re talking about cam to crankshaft timing, remember that the position of the cam is going to change as you torque the cam caps . The cam springs will rotate the cam shaft, which will change the position of the links. The static position is only the starting point.

 

[BumbleBee1]

The distance between crankshaft sprocket and cylinder head doesn't change. that is what has me so confused. Could I have jumped one tooth on the crank that would give me this result??