I'm about to start a few mods, got all the parts and would like to take a full day and get them all done. I was wondering whether it's best to start with one in particular, or if there are a couple that need to be done first before taking on the next. I'm mechanical, though I usually require good instructions. Here are my planned mods for an '05 S40 with 3200 miles on it and I'm at an elevation of 900ft:

A) Raptor petcock
B) Lancer's jet kit (plan on 52.5 pilot and 150 main)
C) K&M air filter (not a cone, but a high flow replacement for stock)
D) Dyna pipe, with ryca spacer and new 7" heat shield to cover joint
E) Oil and filter change
F) Pull engine/clutch cover and regasket (very slow leak seems to be originating there)
G) Relocate aftermarket rear turn signal lights to license plate bracket (for room for bags).
H) Install saddlebag supports
I) Install saddlebags

Assuming the last three can be done anytime, any advice on what to do first? Carb work has me most worried, but I can handle it. I'm assuming I'd drain oil, change filter, check the timing chain tensioner (didn't get the Versy mod), seal up the cover, pull carb and install jets, install petcock, change the air filter and put on the dyna and be good to go.

Am I nuts for trying this with only this site and my owners manual for reference? Really appreciate the advice, it'll help with my nerves for taking on so much (for me).

thecoolerking wrote on 07/30/13 at 12:03:47:


If so, then we're a pair of nuts.  

Id grab a 1/4" ratchet & see if I could gently snug the side cover up.

Thanks everyone. I think I'll get started on Friday with b-f.  Appreciate all the advice.

Good to be surrounded by so many mixed nuts. Told my HD friends what I was planning and they couldn't imagine it. They just take it down to the dealership, even to change oil.

Thanks again

When you pull the clutch cover off, make sure to pull out the little rubber bung with the wire from the crankcase. Clean up really well, get all the oil out of there and seal it with some of the blue sensor safe silicone (or the grey Harley stuff, or the orange Yamaha stuff). The clear general purpose silicone isn't so oil resistant in my experience.

Carb removal for jets? Why, you can just loosen the clamps and turn the carb toward the drive side of the bike. Pop off the bowl, pull the float, swap jets and reassemble. Good project while the engine oil is draining.

Then swap your oil filter and add the new oil.

Air filter whenever you feel like it, same for the lights and the bag supports.

You can change the case gasket while the oil is out for an easier/cleaner job. FYI, no matter how well you seal up around it, the neutral position indicator wires will leak a bit unless you fully degrease the pass through and pack it with gasket goop. The base of my engine looks like an old AMF era Shovelhead there are so many weeping spots. You get used to it, just hose it off with brake cleaner occasionally.

Carb will rotate either direction, mine goes best top toward belt, base toward brake. The base screws can be a bit of a nuisance to remove, But they will come out, couple drops of PB or similar penetrating oil helps a lot. And if a head strips, take them out with vise grips and go get stainless allen head versions.

9 hours almost to the minute between our posts... not bad.