Spa day for the Warthog (Major maintenance on a DL1K) - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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  #1  
Old 12-15-2012, 12:23 PM
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Default Spa day for the Warthog (Major maintenance on a DL1K)

Spa day for the Warthog

Bit of a repeat from another thread, but I thought I'd post a thread for a spruce-up of my V-Strom, aka "The Warthog". So named for it's homely appearance, this is the bike you love not so much for looks, but for character and personality.

in 2006 I bought this bike sight unseen from a guy in Portland Oregon: A 2003 Suzuki V-Strom 1000, the one pictured in my avatar. It had been fitted out with Happy Trails bags and crash bars and taken to Panama and back by the PO, had been lightly lowsided on each side a few times, is a little dented here and there, a little rashed. I lived near Boston at the time, and flew out a couple of times a year and toured the northwest, often with my brother who lived near Portland. I've put about 20K on the bike like this, all around Oregon and Washington, out as far as Glacier National Park, up through Alberta and a little bit of BC, down and back to SFO twice, and then down through Oregon and Utah to Tuscon Arizona, where it has been for a year and a half or so. I've pretty well lapped Arizona on it, and then this spring rode it up here through Death Valley and along Highway 1 via Morro Bay. It's got about 53K miles on it by now.

I haven't really neglected this bike to any bad extent, it's had regular oil changes and tires, valves were checked at about 45K miles, filters have been done a few times. I had a shop in PDX do some clutch basket repairs to cure the chudder, and also installed an upgraded shock spring and spacer and uprated fork springs and added a PowerCommander USB to fix the lean fueling issues it had stock. But other than that the bike has had very little love, and that is a departure for me - my bikes are usually in pretty top running order. This bike was just 3000 miles away from me and my tools for 50 weeks a year and so it was often 'ridden hard and put away wet'. It frankly owes me nothing - I've had such tremendous adventures on it, and it's been very reliable. If it blew up I'd give it a hug and a viking funeral and be glad for it. But it needs a good going-over before it goes back to Arizona, tires, brakes, better accessory wiring, a lot of cleaning and lubrication, and more.

I just did hydraulic fluid swap last weekend plus rear brake pads and put on a newly-recharged stock shock that was reworked by Jay Jobes (aka Sasquatch). This week I will pull off the wheels, clean and check the wheels and bearings, get the tires mounted and balanced, and see about the chain and sprockets. There's a fairing crack to repair, and I might update the PCIII map, and a bunch of other odds and ends like plugs, filters, TB sync, etc.

Last night I repaired a stripped oil drain plug, and I'll detail that next.
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.
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  #2  
Old 12-15-2012, 12:28 PM
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Here's the patient:



I had previously repaired a stripped oil drain bolt, that is detailed in a How-to here:

DL1K: How to repair a stripped oil plug

Timesert:



Safety drilled...


and done:
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.

Last edited by Noblehops; 12-15-2012 at 12:30 PM.
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Old 12-15-2012, 12:38 PM
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Some a$$hole did this (OK, it was me). I know better now. I will fix it.



Chain, sprockets, cush rubbers all worn out. Going up two teeth on the rear sprocket while I do this. Rear rotor is too thin, needs replacement:



Needs tires, new valve stems, replacing the wheel bearings, and sent the front rotors off for grinding, as we are doing a brake upgrade while we do this:



Oh, that steering head feels notchy now that the wheel is off of it. Off with it's (steering) head!
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.
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Old 12-15-2012, 12:49 PM
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This windshield sucks.

I mean I actually like the height and shape, but it's been abused. It looks like it was cleaned with a thousand Central American squeegees during a water shortage, and it probably was.


With nothing to lose I bought one of those 3M headlight restoration kits.



I figured that the fairing was doing a good of of holding it as it is, so I masked it at the edges in place, cut along the edge, had at it. Duck or no dinner.

Step 1: Destroy your windshield


Step 2-5: Fix it, in a few steps


Step 6: Polish it


Step 7: Victory!


I'd say I got a B+ result, I believe A+ is possible if I did both sides and did more polish to the front. I might work more on the front, as I have plenty of supplies left in the kit, but I am plenty happy with it just as it is. Took about an hour all in all. Use a corded drill and cover the bike. Follow the instructions.

This kicked ass.
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.
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Old 12-15-2012, 12:55 PM
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Got a new set of bars to replace the buckhorns that were on it. Protaper SE ATV Hi, very close to my GS' in shape and also 32" wide. Very interested in how this will change the ride.



Did not realize they came with a crossbar, cut off the clamp and removed it:



"Walked off' the old grips with the airgun:





Pulled the trigger on a complete set of SV1000 brakes including steel lines and radial master cylinder, so removed my current brakes entire:




More...
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.
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Old 12-15-2012, 01:01 PM
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Managed to beat the lower bearing of the steering stem with surprisingly little aggro, compared to the last two times I did this. I might be learning something after all





Popped the races out with an awesome Park Tools race extractor:





...
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.
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Old 12-15-2012, 01:18 PM
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Had a broken left side cowl, had been held together with duct tape for a couple of years, but it was rattling and the crack was getting worse, and the lower black piece was unsecured as I learned. Oh and it looked ghetto



Kludged a fix by clamping the threaded insert to the stub of the boss, and then encasing it in JB Weld, after cleaning and sanding the plastic. Taped the panel together from the front including over the hole, and the JB Weld filled the gap nicely.





Let that cure up and then overlaid two sheets of fiberglass mat and resin.



It set up hard and strong, and the JB Weld had bridged the missing part nicely with the tape there to make a smooth surface. Put it back together, pulled the tape off the front, and declared victory.



Pulled off the Autocom and radar detector wiring, and re-routed the accessory plug to the front cowl, which will double as my battery charger plug.



Downloaded new software, firmware and maps for the PCIII USB, will load those soon.

Got my new tires mounted and balanced and the wheels cleaned up. Got impulsive and ordered RaceTech gold valves for the fork. Restraint is overrated

...
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.
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Old 12-15-2012, 01:21 PM
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More (but no photos). I checked the valve clearances and found them all smack in the middle of the tolerance. They had been checked at a shop about 15K ago, and the work order said nothing about any shims, not that it necessarily would have, but they appear to be stable as many other owners have reported. HAPPY DAY.

I measured and synched the secondary butterflies to within 2/100 of a mm. Calling that good. Put a drop of lurid red nail polish on the adjustment screw for good measure.

Will install extensions to the throttle body sync ports when I sync the throttle bodies to make that fast and easy in the future.

Downloaded new maps and firmware for the PowerCommander III and will install them when I fire it back up.

Had to bypass the fuel filter integral with the pump a few years ago and install an inline filter downstream of the tank to the fuel rail - replaced that today.



Uh oh. Was losing clutch fluid and I thought it was just a leak at the banjo. Not so. It's leaking from the business end of the slave cylinder:



More...
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.
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  #9  
Old 12-15-2012, 01:23 PM
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...lots of hardened schmutz around the seal area. This part was redesigned with a secondary seal akin to a 'dust seal' on a brake caliper. My bad chain hygiene no doubt contributed to this seal's demise, as it lives under the sprocket cover, nominally shielded from the carnage within, but not really.



Took it apart to see if it could be repaired with a new seal, cleaned it all up. Tried a set of rotary abrasive brushes (Bench Buddies) to see if I could hone the bore a bit:





No joy. Too much pitting in the seal area of the cylinder. I'm going to have to spring for the new updated part.



...
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Nils Menten - Santa Cruz, CA, USA

R1200GS, DL1K3, CBX, DRZ
I have a motorcycle problem.
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  #10  
Old 12-15-2012, 01:49 PM
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No kidding, definitely a spa trip! Anyways, please let me know how the bars change the ride/feel/etc. I'm thinking of swapping mine(stock originals) because I HATE the way they feel. If possible, would you be willing/able to post a picture of the two bars right next to each other, just to show the difference? If not, no big deal!

Also, is that really the same shield, just polished up? If so,

Thanks for sharing the pictures!
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