Fairings Painted

Thanks to K&F Customs Panel & Paint for their hard work repairing all the small fibreglass imperfections and working their magic with the paint. The colour choice was Mazda Brilliant Black with a layer of silver flake over the top. POSH Aero Sharp indicators and N PROJECT mirrors were installed at the same time too.

Full fairing kit on/off:

Closer details:

General Servicing

With everything else on the bike sorted the remaining running gear needed to be serviced. This included the battery, spark plugs, brakes, brake lines, brake fluid, rear brake reservoir, coolant, engine oil and oil filter. Other things that will need to be addressed in future are tyres and front brake pads.

To start, the engine was serviced with full synthetic Penrite 10w-40 oil and a Hiflofiltro HP111 oil filter.

In order to clean the coolant system a 50/50 mix of cleaning vinegar/water was ran at operating temperature, then a second time with just water to flush the system before finally being filled with Toyota Red coolant. A new coolant overflow bottle was made up too, mounted from a bracket behind the radiator to replace the original overflow tank that usually sits behind the engine.

The original battery dropped a cell on the first attempt to turn the engine over so a replacement was needed. Lithium batteries are surprisingly cheap now and weigh about 1/3 of a normal liquid battery, making the SSB Powersport Lithium battery a great replacement. I also replaced the spark plugs with NGK Iridium CR9EHIX-9 spark plugs which are less prone to fouling.

HEL braided lines were fitted including a HRC rear brake reservior kit before both systems were filled and bled.

Valve Clearance Check

After all the effort put into getting things perfect on this bike, it was always going to be impossible to have peace of mind without making sure the valve clearances were within spec; even if the adjustment on the previous engine came to unfortunate outcome due to my mistake. Thankfully the clearances had been done fairly recently on this motor as they were all within spec and the cams, holders and shims could all stay where they were.

For reference, these were the measurements:

CYLINDER 1:
Exhaust (1, 2): 0.229, 0.229
Intake (3, 4): 0.178, 0.152

CYLINDER 2:
Exhaust (1, 2): 0.203, 0.203
Intake (3, 4): 0.178, 0.178

CYLINDER 3:
Exhaust (1, 2): 0.229, 0.229
Intake (3, 4): 0.178, 0.178

CYLINDER 4:
Exhaust (1, 2): 0.203, 0.229
Intake (3, 4): 0.178, 0.178

ACCEPTABLE TOLERANCE:
Exhaust: 0.200 - 0.260
Intake: 0.130 - 0.190

Rearset Modification

The stock rearsets can become problematic when it comes to full lean clearance and while they do pivot to adjust for this, personally the idea of scraping the pegs doesn't sound like a good time. Originally I planned to go aftermarket but decided instead to use brackets to replicate a similar footpeg position that aftermarket rearsets provide. Cardboard was used to make templates first before being transferred to the aluminum flatbar and cut out to fit. The final result are stock rearsets that now sit 50mm higher and 30mm further back.