I guess I'm just maintaining this as a page to list the work I've completed on my Uly. I didn't like the fuel map I got from Rev-Mo. It feels like the bike is running way, way too rich. Coughing through the intake, slow acceleration off the stop, and hesitation at lower RPM. I reinstalled the stock map, and am going to send the ECM out to IDS for the appropriate aftermarket map to be installed. They did recommend I plug the extra holes in the intake that a previous owner had drilled. Apparently this can also cause problems.
I also repaired the exhaust valve actuator and reactivated it using the Buelltooth. Love the sound when I honk on the throttle!
Here's how I plugged the holes in the intake:
I bought a piece of Kydex as it is obviously mold-able with heat. To make the template, I laid strips of 1.5" wide painters tape on the air box to get the compound curve. I marked the outline of the box with pencil, then peeled the tape template up, and put it on a piece of paper so I could cut it out. I then transferred that flat shape onto the Kydex sheet and cut it out. Sanded the sharp corners off with the disc sander.
I formed the Kydex to the shape of the air box by heating it up and pressing/holding it against the airbox until it was cool enough to take the shape.
Next, I sanded the air box and the Kydex with 120 grit, and mixed up some JB Weld plastic epoxy. I wiped the airbox and the Kydex off with some acetone, and spread the glue evenly onto the Kydex and clamped it onto the air box.
Seems to be a good repair, and will hopefully have accomplished the goal.
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