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Discussion Starter · #1 ·
Well you can only be on this site for so long before you look at some of the mods Devious has done and start to wonder to yourself "why not?". Such was the case this spring. I think the day that finally put me over the edge was the AMA Superbike opener, Up here it means spring will be here soon. Gathering parts was easy.

Zard slip-on $400 (Trat groupbuy)
SAI block off plates $100 (Many thanks to Kulhka)
Tuneboy $396 (www.newspeed3.com)
Carbide burr $30 (Ace hardware)
K&N filter $45 (steiger powersports)
Ceramic coating $100 (K&A Coatings)

Total cost: $1071


As I waited for parts to start arriving I decided I'd try my hand at porting the headers and take out the pre-cat and SAI.
 

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Dfib said:
Zard slip-on $400 (Trat groupbuy)
SAI block off plates $100 (Many thanks to Kulhka)
Tuneboy $396 (www.newspeed3.com)
Carbide burr $30 (Ace hardware)
K&N filter $45 (steiger powersports)
Ceramic coating $100 (K&A Coatings)

Total cost: $1071
The feeling of making your bike faster all by yourself - PRICELESS
 

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Discussion Starter · #3 ·
Day 1: Disassembly

Plastic and tank off (easy stuff so no need to write too much here)
Airbox removed (I always forget that dang screw right in the middle and look like a moron trying to pull the airbox cover off!
Stock midpipe and cans removed.
Screws holding the radiator and oil cooler removed. (I found it way easier to work on the header bolts by removing the support brackets for the radiator and oil cooler too.)
Header unbolted and removed. (that went so well I was begining to wonder what catastrophic pailure was in the future)

Here is a pic of the SAI system under the airbox:


I unplugged the solenoid and took the reed covers and reeds off. Put the block off plates on. Here's a pic of the block off plates in action.


I'm amazed looking at the bike now how much room the SAI took up under the airbox... I have to believe there is better airflow with it out of there, but without actual testing I'll never know.
 

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Discussion Starter · #4 ·
Day 1: Header porting

OK deep breath here I go. I used the carbide burr I had gotten to start removing material on the header. HOLY SHIT those burrs remove A LOT of metal! Here's a pic of one in the works:

The right side has been attacked the left is waiting for it's turn. The burr left some ridges inside which were cleaned up with sanding rolls.
 

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Discussion Starter · #5 ·
Day 1: Pre-cat removal:

After porting the headers I got ready to pull the pre-cat. 
Actually this was by far the easiest and least time consuming job in the whole project.
Using a 1/4" drill bit I drilled out 3 of the 4 studs holding the pre-cat in.  Next I beat the remaing stud a little with an air chisel (not necessary, but air tools are fun dangit!)

Here's the drill hole on the pipe:


And the pre-cat on it's way out:



Went to go weld it up, and Ace Hardware's rental welder was out of the shop. :violent1:
Remembering a post on here (Sorry too lazy to go looking, but thanks to the one who posted it) I went to an auto shop that does exhaust looking for someone to do the welds.  Turns out the shop I went to is run by a bunch of bike nuts.  After talking they relized they knew my bike from past bike nights at the local drive-in, and after a little BS session they ended up doing the welding free of charge! :drink:  Ok technically I tried like hell to give them a little something for their time, and we settled on me buying a round of home-made rootbeer next bike night. :beer:
 

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Discussion Starter · #6 ·
Day 1 Finishing up:

Tools all picked up and put away and took the header and new Zard pipe to K&A Coatings http://www.kandacoatings.com/ 35 minute drive, but they are very nice and turn around time was 4 business days! They did the sand blasting and coating for $100 (special friend discount - their cousin sent me ;D) When I picked it up I noticed they coated the inside of the headers too! Makes it pretty sooth in there as far as I could feel.
 

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Discussion Starter · #7 ·
Putting it together:

Got the parts back from ceramic coat and picked up some header wrap while they were gone. Advanced auto parts carries 1"x50' black fiberglass wrap. The black was lightere than the ceramic coat so I picked up some header paint with ceramic in it. Wrapping the headers was a PITA! They are close enough together by the collector that it took a try or two to get it right. I started at the bottom and wrapped to the ports. 50' was enough but I only had a foot or two left over. A quick shot of the header paint and good to go. While the paint dried I worked on getting the db killer out of the Zard. My roommate and i tried like hell until I remembered CB talking about a spot weld they put in. 1 minute with the drill later and I was good to go. Reassembly was easy and generally went well. Here she is now:



 

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Very nice!
The black exhaust looks great on the white bike.

Do you have plans to black out the radiator cowl, and rear sets?
Oh, and did you bleed on it?
 

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Discussion Starter · #11 ·
Sorry guys my internet took a dump when I tried to post the last chapter.

The not so good:

Before I put the bike back together (and being grinding tools are a lot of fun) I decided to try my hand at radiusing the butterflies on the throttle bode. Removal is very easy. Two screws and the butterfly will slide right out. If I were to try again I'd do the work with out power tools.... I was very worried I had removed too much metal, but everything seems to be ok.

Impressions:

Zard sounds great..... It really growls! Love it!
Make a couple of hops around town out of necessity today, and the bike runs great. The biggest notice right now is the throttle is snappier. I need to get the tuneboy and get a tune in before it gets tested. Seat of the pants acceleration feels better too! Hopefully I'll be able to find a place to do a couple dyno runs so I know where I'm at.

Special thanks to all those who encouraged and answered my frantic questions along the way!
 

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Discussion Starter · #13 ·
Devious2xs said:
Very nice!
The black exhaust looks great on the white bike.

Do you have plans to black out the radiator cowl, and rear sets?
Oh, and did you bleed on it?
No blood this time..... But she's drank from me before.

As for the rear sets and cowl, it may be a future project. Annodized blue might be interesting too,something to match the lettering on the tank. I think caswells "fast blue" dye is a really close match.

Next up grades will prob be hypertech front on Ohlins rear suspension.

Of couse the thought of a turbo is sure interesting.......... :popcorn:
 

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Discussion Starter · #15 ·
briank said:
glad to see you have the fast white color option ;D
Vid/sound clip of Zard, nothing too exciting. Lower quality shot later in the afternoon with digital camera:
[video=youtube;KxZfCktGk28]http://www.youtube.com/watch?v=KxZfCktGk28]http://www.youtube.com/watch?v=KxZfCktGk28[/video]
 

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Dfib said:
Sorry guys my internet took a dump when I tried to post the last chapter.

The not so good:

Before I put the bike back together (and being grinding tools are a lot of fun) I decided to try my hand at radiusing the butterflies on the throttle bode. Removal is very easy. Two screws and the butterfly will slide right out. If I were to try again I'd do the work with out power tools.... I was very worried I had removed too much metal, but everything seems to be ok.

Impressions:

Zard sounds great..... It really growls! Love it!
Make a couple of hops around town out of necessity today, and the bike runs great. The biggest notice right now is the throttle is snappier. I need to get the tuneboy and get a tune in before it gets tested. Seat of the pants acceleration feels better too! Hopefully I'll be able to find a place to do a couple dyno runs so I know where I'm at.

Special thanks to all those who encouraged and answered my frantic questions along the way!
The screws for the butterflies are staked in place on the bottom (hit with a pin punch to spread out the bottoms). When you put them back in, do the same, and use thread-lock like Locktite.

The new tune will make a huge difference in how the bike performs with the improved airflow.
Glad to see the DIY bug is contagious. :wrench:

PS - "Frantic" is an accurate description. ;)
 

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Discussion Starter · #18 ·
Finally done:

Got the tuneboy the otherday while at work, so I had to wait to get home to send in the serial# for the ECU. Piece of cake right? ECU sent off and hours drag by as I'm paitently waiting a reply from tuneboy.........

Finally last night 9pm I get an email back saying no code for you!!

It turns out if you buy the tuneboy from another vender it is their responsibility to get you the code! :violent1: That would have been a handy piece of information to have! :finger:

Email sent to the newspeed3.com and got a reply back very fast!

Today the new tune has been loaded (DVS,'s 20088_base2 tune [available right here in "downloads"] with mods for sprocket changes added).

Impressions: HOLY SHIT!!! Throttle response is 100 x better, no popping on decel, seat of the pants dyno says hp/torque jumped. Cracking the throttle aggressivly in second immediately results in the front tire climbing! Everything was well worth the time/$$! Now just have to line up a little dyno time to get her fully settled in!
 

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GREAT

Be careful in the twisties until you get a good feel for the bike. It is almost like starting all over. 8)

Welcome to the Mod Squad :wrench:
 
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