Gidday,
there is not real point to this e-mail other than letting you know that MY BABY BUSRA FEELS LIKE NEW AGAIN!
after way over 120,000km's of thrashing the ring out of her, i bit the bullet after my second gear dogs went for the second time.
i pondered on getting an 08, but then changed my mind because i am a wee bit attached to BUsra....
she was getting quite noisy in the engine, as i have not exactly given her an oil change every 5000'km.s ( more like every 25,000...)
SO,
i pulled the whole bike apart.
new rings, hearings, gearbox, shiift forks, rails. seals, gaskets, timing chain+ guides, tensioner, oilpump, waterpump,
very very near new front forks+ tripple+ top plate, rear shock/spring, front calipers, rear caliper, chain, sprocket. new axles and adjusters f+rear, bearings, seals.....etc
got the polished wheels rolled back to perfection!
new rubber....
nearly everything!
the gearbox i got was from an 06 with nearly no KM"s and my shifts are much better than they EVER were with the old box.
Man, she runs like she did ( AND BETTER)like when i got in 2000 with 1500km's on the clock.
sweeet like chocolate!!
after christmas i have a few bits to address
rear disk
injectors ( get them cleaned)
fuel pump ( still the origional) going to a bosch 044 and FMU in readyness for BOOST)
reshim the valves, ( they were suprisingly not that far out from factory settings!)
new radiator ( plenty battle scars from some off road adventures that i should have taken the 4WD instead)
new fanblade( melted ends on mine)
ahhhh, im in love doubletime again!
Jes
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Sounds good , Jess. Maybe if you're going on any more of those off road adventures you should put some barkbusters on, too. 
It's a week by week charade.
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Sounds like a great job Jes and a good exercise in seeing what really needs doing on a high mileage busa.
I suppose some gearboxes are just not good from the start.
My old busa had 115,000 ks on it when I passed it back to Crumpy and the box was still perfect but some of the things on your list are definitely a "MUST DO" at about 100,000 ks.
I had replaced the clutch wear plates, wheel bearings, brake lines and rear rotor as well as cleaning the injectors and fuel system.
Like yours, the shims were checked and still on the factory settings.
I think Crumpy has since done a few essentials as well, like the headstock bearing and steering damper.
You really can't complain about the long life expectancy of a GEN 1 busa.
"If time catches up with you. You're going too slow!"
Regards BUSGO
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Great to see bike you happy to rebuild rather than throw it away. Most people would just trade it or wreck it.
Good inspiring story.
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Can we ask how much you spent on your upgrade? 
Cheers Taub
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Sice you seem to be into the guts of your own machine I'll ask you. One thing I found out about my Busa once I had gotten used to it and started opening it up a bit, the bugger slips in and out of 3rd gear under fairly hard acceleration!!! Only 9000 genuine kms on the clock, any ideas as to what would have caused this to happen to such a young in mileage bike and also what appears to be a very well looked after example?? And that was 3rd gear NOT 2nd which you would expect!! One thing about this bike the gear change has always been a bit notchy too, quite hard to get used to..... I guess it's time to undercut the gearbox, any other suggestions??
Al
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Maybe it is not run in yet?
The gearbox gets smoother as it gets older on the GEN 1 bikes.
Using the recommended oil won't hurt either.
If you mean by "under fairly hard acceleration", dragging, then listen to the answers by the track guys.
"If time catches up with you. You're going too slow!"
Regards BUSGO
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Albertross Wrote:Sice you seem to be into the guts of your own machine I'll ask you. One thing I found out about my Busa once I had gotten used to it and started opening it up a bit, the bugger slips in and out of 3rd gear under fairly hard acceleration!!! Only 9000 genuine kms on the clock, any ideas as to what would have caused this to happen to such a young in mileage bike and also what appears to be a very well looked after example?? And that was 3rd gear NOT 2nd which you would expect!! One thing about this bike the gear change has always been a bit notchy too, quite hard to get used to..... I guess it's time to undercut the gearbox, any other suggestions??
Al
This isn't as rare as one would expect and appears on 2003 onward models. Never happened in earlier models.
Despite many people contacing Suzuki, they never recalled it...
rjw3105 Wrote:Sounds good , Jess. Maybe if you're going on any more of those off road adventures you should put some barkbusters on, too. :) i needed it some tracks i went on..ehehehehe
Taubusa Wrote:Can we ask how much you spent on your upgrade?
i bought most stuff from teh states when the dollar was over 90 :) so it was very cheap. But I never keep tabs of what i spend.....easier on the mind= easier on the wallet :)
Albertross Wrote:Sice you seem to be into the guts of your own machine I'll ask you. One thing I found out about my Busa once I had gotten used to it and started opening it up a bit, the bugger slips in and out of 3rd gear under fairly hard acceleration!!! Only 9000 genuine kms on the clock, any ideas as to what would have caused this to happen to such a young in mileage bike and also what appears to be a very well looked after example?? And that was 3rd gear NOT 2nd which you would expect!! One thing about this bike the gear change has always been a bit notchy too, quite hard to get used to..... I guess it's time to undercut the gearbox, any other suggestions??
Al
it probably is not sitting into gear properly due to the shifter/foot position
but i can tell you that when i put the late model biox in mine with new forks, drum and shafts, it transformed the shift.
It only takes one bang out of gear to bend the shaft slightly enough to create a problem, even teh fork.
It coudl also be that they are bending the shafts when origionaly building the engine and putting it together?
for the price of getting it undercut, get a whole used low mileage tranny from the states. My gearbox COMPLETE with all forks, shafts, drum, bearings and sprocket out of a 2000km old wreck cost 260$ AUD delivered to my door.
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