Hello everyone. It's been a long time since I have posted any thing on the site.
My 03 954 has 46,000 klms on her now and she's starting to show the signs of abuse from before I got her. Friends of mine are saying that I'm blowing out blue oil smoke under deceleration (bad valve seals I believe). Last night second gear dropped out on me. The dreaded piston slap is there even after warm up.
Before I got the bike I knew it was badly treated. It had been sitting for eight years with out protection. Had been used as a motocross bike I heard. Aswell being run with out a proper sealing airbox. So it has been dusted.
I'm certain that the block will need to be rounded out again. I got a quote from LM ELECTROPLATING saying it would be $1000 AUD for a worst case scenario job. still $1800 cheaper than a new OEM case. Bearing in mind this will be Nikcasil plating. For those who wonder, Nikcasil is not directly compatible with the Alusil coating the 954's have.
If I have the money I plan on doing some weight matching to try make the engine smoother and last a tad bit longer
With the gear box I'm thinking of buying a second hand motor or just a new complete set will be the go as a few shops have quoted well over the price of the new OEM set. Again knowing I might only have to replace one gear that may have bad dogs. I'll just have to wait and see.
I have a decent background in motors being 22. But most of that is in light automotive and heavy diesel. I have always serviced my bikes from since I can first remember dad teaching me. #sidetracked.
So other than the general overhaul parts that Ive listed here.
Main journal and big end bearings
Valve seat facing and guides
Twenty thousand bloody circlips
Torque to yield bolts
And so on
I'm hoping Bladeracer or Ian will chime in on this and give any info on nuances of the 954.
Also my main goal with this rebuild would be a good solid engine (not that the 954s aren't) back to stock or slightly higher HP. I don't have figures on the exact ponies yet but there is a dyno day on the 5 of next month, I feel she may have 115- 123 horses.