Suzuki Hayabusa Tear Down

[kballowe]

2007 Suzuki Hayabusa. Purchased with 6k, now has 40K+ miles
3K OCI's w filter @ 6k with Rotella 15W-40 from 6k until present

Daily commuter (12 miles one way to work) and ridden anytime the temps are above freezing.
This bike gets a lot of short to moderate trips.

Stored outside, under a full cover until last year. Now lives in climate-controlled walk-out basement.

Reason for tear down: 1st gear would pop in and out. It was like this from the day that it was purchased, but a minor problem that only got worse to the point that 1st gear was unusable.

It is common for this model to have that problem with 2nd gear, so I wondered why this one was different.

Judging from the shifting forks, the previous owner was a "foot stomper", or perhaps the bike was in some sort of accident. The shifting forks slightly bent, and all three forks out of spec, as well as the grooves that they fit in.

Dogs on 1st gear slightly rounded - which I believe was due to the bent shifting forks.

1. Motor out of bike
2. Motor split
3. Motor reassembled, all cleaned up and ready to go back into bike
.
.
.

 

[Schmoe]

Cool!!!!

 

[Finn]

What is the tubing for in the last picture?

 

[kballowe]

Originally Posted By: Finn
What is the tubing for in the last picture?


Air injection/emissions.

 

[FowVay]

I love the Hayabusa. It's one of those impressive machines than never seems to grow old.

 

[sunruh]

looks like a whole lot of NO wear.

whats up with that?

very nice!!!

 

[BillyTheKid]

Hope you replaced the forks and other tranny parts that were questionable. Did you get the tranny back cut while doing this?

 

[kballowe]

Originally Posted By: sunruh
looks like a whole lot of NO wear.

whats up with that?

very nice!!!


It's that nasty, good-for-nothing Rotella.

It had approx 3,100 miles on the oil when we tore it down. I would have expected to see at least a little sludge... What, with all of the short trips.

Very happy

 

[kballowe]

Originally Posted By: BillyTheKid
Hope you replaced the forks and other tranny parts that were questionable. Did you get the tranny back cut while doing this?


Gears 2-6 are undercut. 1st gear is not.

Actually, complete EBay race "take-off" complete transmission, complete with shifting drum, forks -n- shafts and even a new sprocket.

This transmission looked brand new. Couldn't find the slightest wear mark, anywhere.
Certainly, cheaper than buying the piece parts ...

Did spend some time with the mics and dial calipers to make sure.

 

[kballowe]

 

[Finn]

Thanks. Didn't expect to see emissions system apart from possible catalysator in a bike. Then again I'm lost with new bike technology.

Hayabusa is an impressive bike.

 

[kballowe]

Just to be clear - this is not my bike.
Just doing this for a good friend.

I'm too old for riding one of those. I have an FJR1300. It's an old man's sport bike.

 

[KernelK]

Did you pull the rod bearing caps?

 

[kballowe]

Originally Posted By: KernelK
Did you pull the rod bearing caps?


No

 

[Finn]

FJR1300 is a formidable bike. Had a chance to test it when it was introduced.

 

[kballowe]

Originally Posted By: Finn
FJR1300 is a formidable bike. Had a chance to test it when it was introduced.


It's a nice sport touring bike.
Nothing like the acceleration of a Hayabusa, but much more suited to long trips.
.
.

 

[sunruh]

Originally Posted By: kballowe

This transmission looked brand new. Couldn't find the slightest wear mark, anywhere.


stupid hdeo nonbike oil.

should have cause some wear

 

[kballowe]

Originally Posted By: sunruh
Originally Posted By: kballowe

This transmission looked brand new. Couldn't find the slightest wear mark, anywhere.


stupid hdeo nonbike oil.

should have cause some wear

 

[splineman]

Originally Posted By: Finn
Thanks. Didn't expect to see emissions system apart from possible catalysator in a bike. Then again I'm lost with new bike technology.

Hayabusa is an impressive bike.


My old '73 Chev had the same thing, air injection into the exhaust manifold. I always thought it was cheating...
Nice 'busa. Bet it goes well....

 

[02SE]

Originally Posted By: kballowe
Just to be clear - this is not my bike.
Just doing this for a good friend.

I'm too old for riding one of those. I have an FJR1300. It's an old man's sport bike.

FWIW, the aftermarket for the Hayabusa is huge. You can make the 'Busa just as comfy as the FJR, and still have that 'Busa motor.