I started the 54 yesterday and pulled out of my driveway and before I got to the end of my street which is about 50 feet, I heard a pop from the front of the bike under the gas tank and then the bike stop moving although it was in gear and the clutch was out. My initial thought was that I fouled a plug but the plugs were changed last year. I haven't had a chance to look at the plugs yet, wanted to check with you guys to see what else it could be? The crazy part is the bike still starts, sounds very choppy, and it won't move in gear. Could bad plugs be the cause? Please help?

Water in the tank? maybe the oxygen sensor? any how, get it checked out soon.

Sounds like a plug popped out........

broken clutch cable,. hahahahah????

did you try it in second gear?

if it starts and sounds real choppy...then a plug popped out....i'm almost certain.
did you buy it second hand? do plug work lately? how old is she?

You guys wont believe this shyt....so I'm troubleshooting the problem and removed the airbox to look at the plugs. I found that the first plug did exactly what some of you said, it popped out. I checked the other plugs which seemed okay. After removing all the plugs I first noticed they were Type Denson IUH24D, which is not stock plugs or an appropriate replacement. This plug is used with the 2000-20001 900RR, not recommended for the 2002 954. The 54 uses NGK Iridium IMR9C-9H or Denso VUH27D. I went and purchased a set of NGK IMR9C-9H and started installing and noticed that one of engine housing were the plugs go into were crossed threaded :x To make a long story short, I cannot install one plug because the engine head was crossed threaded when the last spark plug change was done, which is the reason the plug popped out. Now I have to find a new Engine head or have the existing one repaired by a machinist which will require removal of the engine. I purchased the bike used and before I purchased it the guy told me he just had the Honda shop were he lives change the plugs.... :evil:
If anyone know where I can buy a new engine head please let me know. I'm open for other ideas as well. Since I have to drop the motor I plan on doing engine work to increase HP.

you might be able to tap out the existing threads with a spark plug tap coated with grease before pulling the head off. I damned sure would try this first before going through all that work.

I'd take it back to the dealer and say W T F! this needs to be fixed.

you might be able to tap out the existing threads with a spark plug tap coated with grease before pulling the head off. I damned sure would try this first before going through all that work.

try that first definitely. my buddy had this happen on his R1. and he had this done. no problems so far. it's worth a try :wink:

What the hell, I'll try tapping it but I was told not to because of getting metal shavings in the engine.

thats why you put grease on the tap. it holds the shavings. if they did fall into the engine, a shop vac with 5/16 hose taped to the end can go down the plug hole and get the shavings off the piston top.

Chico,

Take that machine back to the shop who installed the plugs. Tell them who's bike it was and see what they can do about it. They are responsible for that problem. I HATE INCOMPETENT mechanics!!! I work as a tech in a dealership and take great pride in my work.... and this type of shit really burns my ass!!!

Good luck w/ fixing it. let us know how it turns out, and the name of the shop who did it.
Thanx Chico

Chico,

Take that machine back to the shop who installed the plugs. Tell them who's bike it was and see what they can do about it. They are responsible for that problem. I HATE INCOMPETENT mechanics!!! I work as a tech in a dealership and take great pride in my work.... and this type of shit really burns my ass!!!

Good luck w/ fixing it. let us know how it turns out, and the name of the shop who did it.
Thanx Chico

:eek: :!: that is crazyness i am a bike mech and i have never stripped anything but i assure you if i did i would rectify the problem... that is definately the dealerships prob. just for piece of mind i asked the owner of my shop and he said without a doubt he would take care of it and insurance would cover the loss!

Here's the latest... I called the shop and explained the problem to no prevail. They said I needed the paperwork proving that the work was done there and believe it or not they even claimed that I could have caused the problem by removing the plug improperly, which is bullshit....after getting nowhere, after a number of phone calls and lots of yelling and cursing I started looking for an alternative solution. I also tried finding the guy who sold me the bike to see if he had the receipt but he has moved and phone numbers changed. I remember he was in the military, which is reason he was selling the bike. Anyway, I talked to a local mechanic who happened to have a 2003 954 motor with 3900 miles on it. He assured me the previous owner rode it like a baby and the engine was in excellent condition. The owner of the 03 engine decided to part out the bike because he damaged the plastics and frame. They agreed to sell it to me for $800 dollars plus installation, can have it installed and ready within 1 week, and give me a 60 day warranty. I think I am going to say phukk it and buy it so I can start riding, it's killing me not being able to ride especially since the weather is great. I took a look at the engine and it looks brand phukkin new, since my bike have over 9k miles maybe I'll be catching a break...

Do the 03 954 have more horse power than the 02 or vice verse? I think I know the answer but, Will the 03 engine fit in the 02 frame?

Any thoughts?

i figured the shop would try to screw you around like that. sounds like you have a good remedy though.

did you try tapping out that hole? i doubt there is any difference in HP between the 02 and 03 and yes they will mount up the same 8)

Heck yeah Chico! Get that motor and then part yours out for some payback!
If you can swing it that is.
Even if not you'll have a whole nother trans, block and whtever to use someday or even sell with the bike if you ever sell it. :)

on the power issue I have seen charts of 02's pulling harder than 03's and vice versa.
no difference except for extreeme minor details that you have to do research to find.
most of the changes from the 02 to the 03 was in weight savings of some ounces here and there.

Sounds like a great solution. Fresher motor and no doctored plug holes. Let us know how you make out if this is the way you go.

Just take the head off and Heli-coil the plug hole. It will be as good as new, and you will save alot of money. If you are uncomfortable with a heli-coil... try a product called a "Time-sert" Instead of drilling the threads and inserting a peice of wire shaped like the threads... you will tap the hole and insert a whole new sleeve in it's place. (better sealing)

Just take the head off and Heli-coil the plug hole. It will be as good as new, and you will save alot of money. If you are uncomfortable with a heli-coil... try a product called a "Time-sert" Instead of drilling the threads and inserting a peice of wire shaped like the threads... you will tap the hole and insert a whole new sleeve in it's place. (better sealing)

Update...I really appreciate everyones info. but, I ended up having the 03 motor installed. Put about 300 miles on it this weekend, so far so good. It feels like Im down on HP in the low end, from about 1 - 4K RPM's, I'm assuming this is because I need to hookup the power commander and have the bike remapped. How difficult is it to install a PC? Scotts Damper? Anyone have some good maps they could foward me?

I can field the Scott's but not the PC

The scotts is simple, all you need to do is take out the two tank bolts behinfd the tree, and replace the upper stem bolt, and the Scotts slaps on.

It comes with great directions. Took me about 30 minutes witha Tq wrench and loctite.

installing a pc isn't too hard either.
might need small hands or some patience though.

what exhaust are you running? I have a bunch of maps I can send you if you e-mail me so I can send them as attachments.