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10-12-2016 S1 bigbore, XB12X headers/ intake seals

30-12-2016 - 10-12-2016 Buell S1 bigbore, Buell XB12X headers/ intake seals / rocker gasket

valves cleaned up very nice

lots off fancy stuff on this bike... valve spring shims, to make it easyer for the valve / spring to rotate, the shims are availeble in different thicknesses so you can shim out the spring pressure for each valve :-)

exhaust valves nice tulip shape

lapping in the valve... you want to get right off the black pitting

something like this

little fresh oil on the shims

and valve seals on

trick valve spings... old skool with vibration damper

as are the disks... pain in the ass to put the keys in , but iff there in they lock in good

Uly job... bike is running rough... and coughing allot

little detection... will start with new intake seals

tel tail signs on engine wear... piston rings are starting to wear out when there is much oil in the airfilter ( normal breathers )

so top side loose

noted the front rocker box gasket is also leaking... as we drop the engine anyway... very little work to do this right away

and as we going to change the headers... the exhaust needs to come off.. i will put the strap back a other way... this way it is first thing to the ground

looking a the gras.. it did some time

old model remus front mount... not broken... tells me this bike is been take care off and not hammered to much

my request to the customer was to spray the header stud / nuts with penitrating oil , with 65000 km.. 9 out off 10 the stud break and i need to dril

but that is one

and the other , to day is a good day

engine supported and front bolt out , will clean it an d put some lube on

with the engine rotated down... the rear nuts can be removed... normay these are no problem

header off... the front retainer clip was already so corroded it broke in half.. good we did this now.. next season the pipe would have blown out

so 3 jobs in 1 ... manifold off

side support screw out

and manifold off ... has been leaking... rubbers are hard

now first a little cleaning

before i take the rockerbox off... this is better

top cover off

this gasket was not leaking... so need to take the box off aswell

loosen the screws... note the brown color... that is broken down mineral oil... you will not have this if you use a premium synthetic oil

little bolts out... losen the 4 big ones evenly , the 2 left bolts felt loose

yep that is the one leaking

so a little cleaning

and fresh gasket

as there are no guidepins.. screw in al the bolts.. be fore you start tightening

and slowly bolt down the rocker box and set to TQ

not a fan of silicone but some rocker cover gaskets are a pain... an a little drop will keep it in place

done... next job

intake manifold. cleaned , new gaskets and lubed the idle screw

manifold in place and tighen down evenly

next job.. headers.. need a new stud.. carefull with the length with the thick flanges

O2 sensor off , works best with a tap off a hammer

the old retainer rings front... will mount some new ones

nice stainless 45 mm headers

new retainer clips

and o2 sensor back in.. with a little never seas

you can try with the stock gasket

but best is to use flat ones for this header

using a big scocket is usefull to push the gasket in place

header on ... nice

exhaust on.. check for cleanance , as you can move the header a little

springs on

mnnn worn down idler pulle edge.. i will cut the cover a little more

chin spoiler back on.. checking clearance

and moving up to let the bike run

connector on... zip tie the tps wire to the fuel rail

setting tps for base adjustment

degrease the new headers.. so you will not burn in your greasy finger prints

and she is running... these headers get a very nice color

top back on

and ready to rol

ok Bigbore... this valve key took me 30 minutes :-(and 2 coffee

base gasket marked and cut for clearance

piston down the barrel

and 1 down

with the hold downs, to hold theme in place do they don't bang on the case if we move the crank

mnnnn something tells me this piston should not be mounted following the arrow... i think the valve wil hit the piston

and number 2 down