Bike Build Thread - Skywalker (A New Hope)

**Turbo** · 10-08-2018, 10:22 PM

As we all know, the best way to recover from broken bones is to build a new race bike...
So with a broken shoulder and a bit of down time on my hands, please make welcome my new 2017 S1000RR, project race bike:

It's had a front end impact so that will all need to come apart and see what's what.
At the very least, it's going to need a new fork tube, and the fork foot has it's fender support snapped off.

Closer inspection also reveals the likely crash cause.... Tyre Shine on the ride surface!!

Stripped back most of the rest of the road gear and all in all, not too much else to rectify before starting the conversion.

Happily it came with the dash, ECU and key, so booting it up, it was great to find it's barely run in!

The oem setup, whilst being Euro 6 compliant, manages 200HP in road trim. This will be a great platform on which to build a race bike!!

**Marshy** · 13-08-2018, 07:02 PM

Awesome!!! A bike build!! Me like

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**Ruckos87** · 15-08-2018, 07:24 PM

Skywalker,,,,, I love it!!!!
Keen to see the progression

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**Turbo** · 16-08-2018, 11:10 PM

First thing first, get the front end out to have a look and see what's what...
To do that tho, there is the not-so-easy task of putting the bike on a T-stand with a broken shoulder!

Damage report: One of the fork legs is fine, the other is unfortunately a little worse for wear.
Rather unsurprisingly too, the triples and stem have a good tweak to them and will certainly need replacing.
Happily, the front wheel, discs, speed sensor and axel are all nice and straight tho!

Whilst the front end was coming apart, I decided to take the OEM clip-ons off and get at the new throttle. Since 2015, the BMW have been totally ride by wire. This means that the TPS is in the hand grip with no physical throttle cable at all.
It makes for some great control as far as Traction Control intervention goes, but means the addition of a quick throttle, is far from a simple task!

What I was able to find out tho, was that the company that did the ECU flash for my 2013 S1000RR, offer an advanced flash for the new 17+ as well as a throttle solution to allow quick throw...
So, with a while off the bike due to injury, it's off with the ECU and throttle, and over to Germany!!

I absolutely loved the flash these guys did for my 2013, and they've moved it on a fair few steps for the new ECU. Can't wait to see how it comes back!

Whilst the top triple was off too, I thought it'd be a good idea to grind off the ignition barrel.....

The immobiliser can't be flashed out of the ECU so the way to do an iginition delete, is to keep the key and EWS antenna together, then bridge the ignition wires with a push switch..
You can buy a kit for several hundred dollars, but the end result is the same and it doesn't really save you any weight.
I normally stick mine up here behind the dash.

...and then just add a Jaycar latching, IP rated switch to the fairing stay.

I'll need to get at the shock at some stage so after removing the bent oem footrests, I fitted up super schmick Gilles FXR rearsets to help with peg stands.
To make working in this spot more easy tho, it's off with the MEGA HUGE oem end can... Can't believe how much these things weigh!!

I also thought it would be a good idea to fit up some new GB covers for some extra protection while I'm working on it...

**Leezx10r** · 19-08-2018, 04:50 PM

Bike build thread, subscribe

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**Turbo** · 28-08-2018, 12:22 PM

Being Euro 6 compliant, means that even the breather hoses can't just vent out to the belly pan. The bike has a charcoal fuel filter system which is supposed to filter out any impurities, in line before venting.
The reality is that you get backwash of charcoal particles in your fuel system, which can stuff up your fuel pump, and the filtering doesn't even do what it's intended to do.
It's extra weight too so time to pull it out!

It doesn't photograph well in situ, so here's the void left behind the radiator, where the charcoal canister used to sit. As mentioned, it goes in line with the fuel breather hoses.

The removed charcoal canister itself...

Round the other side of the throttle bodies is a solenoid valve that pumps unused vapours back round to the canister, before being allowed to vent.

No need for that either, so out it comes...

The spider looking part is the summing valve of all four throttle body breather hoses. It's very light, so the easiest thing, for the system removal, is to plug it's outlet hose with a glued bolt, and re-attach the inlet hoses, back to the bike.

Next on the list, whilst I'm in here is the secondary air system removal.
Here is the pair valve, sitting in front of the plugs....

Unbolt it from the cam cover then follow the air hose to the air box and remove that too.

Then swap out the O-rings from the oem pair valve and fit up some new block off plates and and air box plug...

Next on the list for replacement is the heavy oem battery, to be replaced with a shiny new Lithium battery...

I won't be running the big heavy ABS system either, so out it comes...

I'll need to remove the ABS & DTC controller from the plunger system. The controller is on the CAN Bus so it needs to go back in, for the rear wheel speed sensor data to get back to the ECU.
You can buy expensive replacement controller without the plunger unit, but as any associated error codes will be flashed out of my ECU, there is a way to re-do yourself.

First separate the plunger unit from the DTC controller

Then trim down the two prongs, delivering power to the plunger unit...

Seal the controller back up with good quality waterproof tape...

Then re-install back to the bike...

Next disconnect all the brake lines from the ABS module and rip out all the internal hoses... Job done!

Last thing for now is removing the knock sensors... I'm after a fixed timing for best performance with my ECU map to 98 RON fuel. That means the ignition timing "healing", that the oem ECU can do, is not required and in fact is not desirable at all.
The function will be flashed out of the ECU so no need for the sensors...

**Ruckos87** · 31-08-2018, 12:38 PM

Your smashing this out especially considering your still half busted up.

Well done!!!!!

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**Turbo** · 31-08-2018, 06:25 PM

Originally Posted by Plumb

Your smashing this out especially considering your still half busted up.

Well done!!!!!

Hahaha, thanks mate. I really do think it's helping!! Some jobs deff pretty tricky tho...

**Marshy** · 01-09-2018, 03:43 PM

More updates pleeeeeease!

**Turbo** · 01-09-2018, 05:11 PM

Originally Posted by Marshy

More updates pleeeeeease!

Well, it just so happens that a large motorbike parts parcel arrived pretty recently...

Before getting into that tho, got to rip out the old oem Euro 6 system.
SOOOOO heavy, there must be a ridiculous amount of filtering happening in this collector!
To give you an idea of how quiet it is in order to be compliant, the stationary noise test figure is around 80dB!!
I also get to rip out the Lambda sensors and stupid flappers...

With the old headers off, it was a good opportunity to get in and change out the oil and oil filter.
The BMW sump plug can't really be drilled so an aftermarket Titanium cross drilled plug was the go.

Next to fit up the shiny new headers...

Mid pipe... (sensor plugs on the way)

Then the super cool MotoGP style muffler!! BRAAAAAAAAP!! 800dB WHAAAAT???

The end can mounts to the pillion peg, but I reckon it looks kinda weird with the peg removed and potentially a little sharp on a leg, in a crash.
I machined off the ends, and gave it and the supplied bolt, a bit of rattle can love... FACTORY!!

Another feature of Euro 6 compliance, is a standardised OBDII connector for diagnostics, and in my case, the Race Calibration Kit 3.

OBDII is pretty standard, seen in most cars, but I'll need an adapter to connect to the BMW RCK3 computer interface.
I sourced an OBD adapter cable, and will hard wire it into the bike so I can plug in, without removing the tail fairing.
Happily I already have a bunch of room in there, having removed the ABS system...

I ran the other, circular end, just past the battery box and out to the side...

I'll put a locking cap on the connector which will make it waterproof and it can just sit tucked away behind the subframe, until needed..

The next exciting package to arrive was from the good guys at Alpha Racing in Germany. BMW Motorrad's Race Calibration Kit 3 software and motorcycle interface:

I have Race Calibration Kit 2, on my 2013, and it proved itself indispensable for fine tuning traction control and launch control as well as tyre profile etc etc.
The BMW electronics as standard, is setup almost entirely for road use on road tyres. So, getting control over it, to me, is essential to make sure the electronics are helping rather than hindering.
RCK 3 offers the same amount of control as its predecessor, with the added benefit of dedicated and independent wheelie control management and a few extra tweaks. All of it will work alongside the race flash/map for my ECU, that's on its way.

**Leezx10r** · 04-09-2018, 07:10 PM

It gets better and better! Great write up turbo, very excited for the end result.
Keep the posts coming

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**Petefrost** · 29-09-2018, 09:34 PM

Nice work Owen! Did you sell your old one?

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**Wolfie57** · 30-09-2018, 11:08 AM

Ha loving this, soo much work goes into it! And love seeing all the new shiny bits!

**Turbo** · 30-09-2018, 04:27 PM

Originally Posted by Petefrost

Nice work Owen! Did you sell your old one?

Thanks man. Nah, keeping the 2013. Keen to have a backup bike and spend more time on track rather than in the pits with bikes in pieces!

Originally Posted by Wolfie57

Ha loving this, soo much work goes into it! And love seeing all the new shiny bits!

Cheers mate!! It's all worth it for the shiny bits!!

**Turbo** · 30-09-2018, 06:55 PM

A few more bits have begun to arrive and first up is a new air filter.
I was pretty keen on getting one of the lightweight Sprint Filters, but after hearing A HEAP of people have issues with them letting in dust, dirt and sand, I was pretty wary.
I REAAAAALLLY don't want to rebuild a motor again anytime soon, so I'll stick to a known good, BMC:

Next thing to arrive was a quick release fuel cap. In order to get my quick-pour fuel jugs to work, I'll need to nibble out part of the tank inlet.
First job is to mock up the cap in place, and texter out the bit I want to get rid of...

Next to drain the tank and remove the ridiculously large fuel pump/artificial intelligence node...

With the pump out, I was able to get in and fit a rag to the underside of the inlet, to hopefully minimise the amount of metal shards I'd get in there!

Next up, get the nibbler out and go to town on the top side...

Nibbling done, remove the rag and blow out the inside of the tank with A LOT of compressed air. I also wiped around inside with plenty of shop towels, until I was sure to get rid of any bits of metal.
Last step was a quick rinse with petrol before fitting it all back up...

Boom!! Quick-pour action!

With the front end apart, I saw it as a good opportunity to strip down the brake calipers, in preparation for the new Vesrahs to be installed..

Then to fit up the new braided lines, replacing the ABS ones, from the good guys at Hel Australia....

I'm also a big fan of the HRC mini-reservoir so that's fitted to the rear too..

I look forward to fitting the calipers back up with some Titanium cross-drilled caliper bolts, when the front end starts coming back together!

**Petefrost** · 03-10-2018, 08:22 PM

Going well and looking good mate. This time, don’t pinch the o ring when you put the calipers back together!

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**Turbo** · 03-10-2018, 11:58 PM

Thanks man. It seems to be helping the healing process anyway!!

**Turbo** · 04-10-2018, 07:32 PM

I was wandering around my local auto parts store and happened upon some sheets of black or silver "universal mesh".
It turns out to be the exact same material that Radguard are made from. It's pretty cheap too, so in need of a solution, I bought a sheet and marked out the shapes I wanted...

The Radguards are a great product, but on the BMW version there's at least an inch of metal frame, the whole way round the edge, that actually blocks airflow through the radiator and oil cooler...
Here's a pic from my 2013:

With the universal mesh, I was able to get the complete protection from stray stones and rubber etc, but also retain full airflow, with a nice neat fit.
A once over with rattlecan-red and it looks factory!

Earlier in the build I had to remove the charcoal fuel filter that was inline with the fuel breathers. The tank still needs to breathe so I ordered some funky blue fuel hose to re-run it.

This will either vent out to the belly pan or back into the air box, depending on race regs.

Final drive arrived recently too. So, it was off with the old road sprockets....

and on with the new 520 sprockets and captive spacers...

Then, with some help from my able-bodied buddy Marshy... fit the chain too! Thanks mate!!

The finishing touch for the back end was drilling and tapping some holes in the swingarm...

then fitting off a GB shark fin...

**Marshy** · 26-10-2018, 09:10 PM

I'm sooooo enjoying this build thread!!! More updates please!

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**Turbo** · 31-10-2018, 06:19 PM

The bike had a bit of a nasty front end incident, which left the oem triples beyond repair.
I'd upgraded my other bike with the IMA triples and it was night and day what a difference they make.
MUCH more feedback from the front tyre and suspension, an excellent platform to really push from.
The triples have the added bonus of being able to change the offset with the front in assembled!!
So, I was only happy to get another set fitted up...

Also added were some trick new tapered bearings..
Not much needed for fitment, just stick the stem in the freezer for a bit and after packing with grease, heat up the bearings with a heat gun.
Then with a little persuasion, tap them into place (thanks for the help, JohnnyB!!) and when they both come back to air temp, they're not going anywhere!

Boom!!

With the Bitubo forks going to make their way over from the 2013, I thought it'd be a good idea to put a Bitubo gas damper on too...

Then with the triples good to go, I could fit up the forks. For this I talked to my good buddy Rob at Well Sprung.
Rob sorted me out with juggling the internals to the new fork legs and giving them a good service with fresh new oil and seals!!
Amazing and thorough service from Rob, as always!! Anybody that doesn't already know him, really should!!
www.wellsprung.com.au

Then with the forks and triples back in place, I could fit up the clipons and new super-awesome playstation controls from Jet Prime!!

These switches are a SUPER nice product!! Really solid housing and positive action switches. The cabling is also excellent with plenty of jacket and the BMW specific connectors that just plug and play.
It even has Jet Prime written on the heatshrink! lol
Navigating round the various menus and controls is heaps easier than the oem controls. Apart from the oem controls being prone to faults, they also don't crash too well.
If you do get away without damaging the oems ones, but you bend a bar, you then need to carefully mark out and drill a spare bar for all the wee annoying screws. It's really annoying!
These are heaps faster for a quick turnaround, and I reckon pretty damn cool looking to boot!!

**Ruckos87** · 31-10-2018, 08:27 PM

This I like !!!

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**Turbo** · 31-10-2018, 09:58 PM

Hahaha, thanks man!! IMA must have bought a new laser etcher.

They've got logos on pretty well every part now and you can even get your own one wherever you like!

**Mr.Ed** · 01-11-2018, 01:07 PM

Got so close to ordering those same cartridges for my bike... in the end I just couldn't find anyone who ran them so no feedback from anyone I actually knew and I canned the idea.

They do look awesome and are very well priced for gas cartridges!

**Turbo** · 01-11-2018, 07:35 PM

Originally Posted by Mr.Ed

Got so close to ordering those same cartridges for my bike... in the end I just couldn't find anyone who ran them so no feedback from anyone I actually knew and I canned the idea.

They do look awesome and are very well priced for gas cartridges!

I really rate them, Ed. They're pretty well adopted amongst BMW race teams, not widely known about elsewhere tho. Glenn Allerton used to run them back when he was doing SBK on the S1000RR.
Mikey Blair ran them on his R6 for a while too, Lachlan Epis on his ZX6, then there is a whole heap of BSB and SBK teams that run the on Gixxers, R1s and S1Ks.
Even Michael Dunlop runs them at IOMTT!

**Mr.Ed** · 01-11-2018, 07:45 PM

I knew they were good just finding someone who actually had had 1st experience with them and could point me towards someone who would be able to service/set them up for me seemed to be an uphill battle at that stage.

Ended up getting the Mattris off Epis of all people!

**Turbo** · 05-11-2018, 06:01 PM

Originally Posted by Mr.Ed

Ended up getting the Mattris off Epis of all people!

Awesome!! I love the Matris gear too. Of all the aftermarket stuff I've seen, theirs seems to have the best finish.
Hope to try them out one day. Let us know what you think!!

**Turbo** · 05-11-2018, 06:54 PM

The bike is really starting to take shape now and one of my least favourite jobs to do, is the most rewarding to look at when it's done.. NEW FAIRINGS!!
My 2013 ones were pretty scruffy after a recent off, so I took the opportunity to order a second set to match the 2017.
Stage one was the tank and tail fit up....

This allowed fitment of the new stomp grips and some adhesive backed foam, cut out for the seat....

Then fit up the uppers, screens, bellypans , front fenders, add some race numbers then we're almost good to go!!

Still a few more things to go tho, so next up was fitting right-angle valves to the new rims...

Then the re-built Brembo calipers with Vesrah pads, Titanium caliper bolts and braided lines from Hel Australia.

Another shiny new delivery this week just landed from Japan. The forged Galespeed VRC front brake master cylinder!!
I've loved the Brembo 19RCS on the past few builds but the Galespeed is apparently a step up again, from there!
The oem brakes on the BMW are already amazingly good, so I just can't wait to feel how the Galespeed goes!

With the MC good to go, I could fit up the newly modified quick-throw e-throttle and right hand side racing controls from JetPrime...

Again, these buttons are a huge leap forward from the oem block. Really rugged housing that will certainly withstand the rigours of racing, and super speedy fitment/changeover too!

Last up for this section was swapping out the oem grip with some Renthal race grips, and a Brembo low profile reservoir.

BOOOM!! Is it time to go racing yet????!

**Marshy** · 06-11-2018, 12:00 AM

Originally Posted by Turbo

Awesome!! I love the Matris gear too.

Me too! I have it on my racebike.

**Mr.Ed** · 06-11-2018, 11:35 AM

Originally Posted by Marshy

Me too! I have it on my racebike.

Me three! But then again I only have OEM stuff to compare them to

**Kimbo** · 07-11-2018, 07:15 PM

I love my Galespeed M/C

**Turbo** · 13-11-2018, 07:06 PM

A super cool delivery today!! The last piece of the puzzle, new shock from Bitubo!!
I mentioned I was swapping the Gas forks over and I wanted to do the same with the shock. However...
The new bike geometry was revised substantially in 2015 tho, and with the new shock needing to be 40mm longer and with a completely different linkage, there was no way to swap it out and retain the revised geometry.

Sooo, that meant ordering a new shock from Bitubo in Italy. They were kind enough to print my current international ranking on the box too

They custom built this for me after verifying weights and usage etc, then it comes ready to bolt up with preload done and clickers already in the ballpark.

I'd already been talking with them about setup for the other bike, so they were only too happy to help out with revised settings for the forks, after transferring.

Didn't take long to fit up, even comes with a remote preload adjuster!!

Right then, with that fitted and the all-clear from the doc.... I make that just done in time for a track day on Thursday?!!