xb9s teardown and rebuild ?s

[newbueller91]

hey fellow buellers,
this winter im tearing my 2003 xb9s appart and doing some customizing visually and planning on replacing all the gaskets and seals in the motor while i have it out of the frame. for an idea here is current bike,

1) yellow plastics with no chin fairing
2) open airbox delete
3) crankcase breather reroute
4) silver bike other than the plastics and clutch cover( basically the stock look of the 03s)
5) bar end mirrors
6) homemade(selfdone) tail eleminator

planning on going to
1) clear airbox cover
2) orange windscreen and front fender
3) orange ankel gaurds and foot pegs(both rider and passenger)
4) orange triple tree
5) orange rims
6) blue-jean blank tank and swingarm
7) blue-jean black forks
8) custom made buell logo on tank(orange)
9) led turn signals
10) and as said, planning on gasket and seal rebuild
11) and finally ecmspy tune with megalog (once rebuild and reassemblied)

if anyone can think of anyother clever ideas to go along with the theme that would look good please share and the main point of this post is to ask if anyone can share good info on the engine deassembling, i have done engine tear downs and rebuilds before just have never done it with a motorcycle of anykind.

i currently have it in my sparebedroom ready to start but wanted to ask before getting wet and then soked up a creek without a clue , haha

thanks guys,
kody

 

[christianmb]

Anti-Seize, torque wrench, and shop/service manual. Also, get new rocker box to head bolts (the small ones) I kept breaking them on reassembly. Got new ones and problem solved.

Other than that, patience and a large work area are great things to have too!

 

[newbueller91]

thanks chris, my sparebedroom is like a small garage and i even have a workbench in there for wniter projects like this one. and thank you for the advise it will go to good use.[up]

 

[thrstrmech]

pics as you go please...I too have an '03 9s Sunfire Yellow, check out my pics

 

[newbueller91]

no problem, my girl is coming over for the holidays and bringing her nice camera so i will be able to take some great pics for at least a few days, after that ill be using my cheapo slim camera but itll do the job just fine i think.i already have the air box apart and my first layer of paper mache mold in place unfortantly it takes about a day to set so its one layer a night but by monday i should be molding the plexi-glass, ill be sure to get lots of pics of that prosess since i havent found anyone else that has done this or even tried, if anyone has please share tips. im alittle on edge with this one[confused] And Thrstrmech thats a good lookin yellow, your bike looks very clean! [up]

 

[newbueller91]

sorry for the delay guys, the holidays got a little overpriced this year and had to set back the project but hopefully will be starting next week some time or this weekend. please be patient, the pics are comin soon.

 

[newbueller91]

ok so as promised, here are some pics of the bike as it sits, or swings more of.

 

[newbueller91]

and thats how it sits now. next is the wires and sub-frame, then paint.

 

[thrstrmech]

thanks, just removed the seat rails and center tail section for powder coating, need to clean the engine off and see which seal/gaskets are leaking to change 'em out...thank goodness ASB is a 45 minute ride away for parts relocated the license plate yet again, also cut away at the center tail section a notch to allow light for the license plate, which eliminates the stock license plate light altogether...remove the tail light from the center section and you'll see what I'm talking about.

 

[newbueller91]

finally got the mold made, starting the plexi-glass airbox tomorrow

 

[thrstrmech]

nice, hope it comes out well...more pics of the process as you go...here's what I've done, painted the side rails and center tail section and installed the Renthal ultra low bars, black chin fairing, not pictured is the single third eye bar end mirror on the right hand grip

 

[newbueller91]

workin on the outside, ive been at it for about 3 hrs so far, takin a quick break and then gettin back at it,

thrstrmech, your bike is looking great, i love the bars[up]

 

[thrstrmech]

thanks

 

[newbueller91]

givin up for the night, starting again tuesday after work.

 

[newbueller91]

almost there

 

[icecoldcoasty]

that air box is gonna be badass. always wondered what a clear one would look like.

 

[newbueller91]

got the bike back together yesterday, runnin goodish and got the airbox done today, and it does look good, i think. ive gotten mixed feelings from everyone i know, but i love it. ill have pics this weekend and i was thinkin about doing an official bike build thread, thoughts?