Page 1: info and mods
page 2: updates
page 3: installs
page 4: best bang-for-the-buck mods
page 5: old Yamaha xj650 seca

page 6: more pics and vids

page 7: 2007 Suzuki GS500F

INSTALLS rating :  <10min very easy 1 - 10 very hard and annoying >2days __________________________________________________________________

2/24/08 subject: full exhaust system installed
Today I finally installed my Magnaflow y-pipe and Dynomax cat-back combo. This was a very eventful install as everything was RUSTY. First the y-pipe bolts broke but I was prepared and had new bolts ready. Then all 4 manifold studs broke, I was not prepared for this. to fix this me and my friend had to painfully and slowly drill out all the broken studs and replace them with bolts.

After we finally got the new bolts in I put in the y-pipe and attempted to install the cat-back. The whole thing went in fine but I noticed that neither kit (magnaflow or dynomax) came with the gasket between the resonator and y-pipe like stock, so we went to 3 parts stores to find it. We then tightened every thing down (Scott helping) and took the car down.
Major thanks to Scott for helping with install, and Massive props to my mom, Ed, and John for helping and letting me use the shop.

Above is the stock restrictive y-pipe, notice the 90 degree bends and small diameter tubing.
difficulty rating : 5
NOTE: This is the single best mod to do to a SHO, all other mods require y-pipe/cat and catback upgrade to give full potential. DO THIS FIRST!

5/13/08 subject : porting/painting manifold and BBB install
I'm finally happy with the SHO's power, after ALL my other mods , and now these...
and this...
The top is a picture of the Big Bore Butterflies (BBBs) and the lower is a pic of the intake manifold after hand porting it my self. The whole procedure was pretty straight forward and simple, but also time consuming. First I removed the manifold
then disassembled it to remove the stock butterflies. Stock butterflies are on top in the pic below and BBBs are on bottom, see a difference?

here's a close up

The BBBs are 3mm larger than stock, and there are 6 of them, so they flow quite a bit more air when open.
Then to compliment the BBBs I broke out the Roto-zip and ported the runners to match.
ported is in top, stock on bottom
I tried four different kinds of bits to grind the aluminum but only one worked well. First up was a carbide cutting/grinding bit and it worked slowly but steadily, until it broke. Then I tried a grinding stone, it did almost nothing then broke. Next was a sand paper bit which worked fast and wore out faster. The only one that was acceptable ended up being the Zip bit that came with the Roto-zip. It was fast and never dulled or broke, however it did require frequent cleaning which was easy. When I went to port the surge tanks I noticed there were small diameter tubes that extend in to the tanks to feed the butterflies. I figured they had some purpose, perhaps for acoustics, but they were smaller than the stock butterflies let alone the BBBs so I removed them for flow. So far no adverse effects. Only HP.
After porting and cleaning I decided to paint the manifold white and red (The SHO is white with red pin-stripes) before reassembly.
Damn thats SEXY!!!
difficulty rating : 4

10/12/08 subject: custom SHOrt shifter

Sorry upfront for no pics but if you attempt this it is very self explanatory. Heres a parts list:

1. dremmel or roto-zip, get the most powerfull one you can

2. metal cutting disks, try to get the reinforced ones as they last many times longer than ohers

3. after market shift-knob, the stock one will NOT work after this

4. knife, sharp preferably

5. saftey glasses, use them!

The first thing to do is remove shift-knob and shift-boot. Then you need to cut the piece of rubber on the shaft that holds the shift boot up (dont worry the metal underneath will hold it afterwards this just lowers it 1/2" or so). Next you'll need to decide how much you want to shorten the shaft. 1" off the threaded section is what I did because it puts the shifter just below the armrest, any lower and you might have to reach down to shift. BUT for ultimate shortness cut all the threaded section off. this will shirten the shift-rod 2"+. Now is the most important step, PUT ON SAFTEY GLASSES . After you PUT ON SAFTEY GLASSES you can start cutting. Cut the metal rod to the desired length, then lastly reinstall shift-boot and install aftermarket shift-knob. This mod is very worth it in my opinion, but it is irreversible.

difficulty rating: 2

2/17/09 subject: shifter bushings

last week I got urethane shifter bushings from SHOsource and installed them in about 1/2 hour. All thats done is 1 jack the car up and put it on stands 2 un bolt the large bolt holding the large shifter rod to the trans case 3 pull off the thread lock washer and remove the bolt 4 wiggle, twist, and pull the large metal tube out of the old rubber soft bushings then pull out the old bushings. and install is reverse of removal, wd40 helps for both removal and install. See how simple? Now Drive it, feels like a whole new tranny doesnt it? I couldn't believe how much better shifting is. What once felt like rubber-bands moving the gears now feels like well oiled ball-bearings. Best $15 ever.

difficulty rating: 1; easyest thing I've ever done to a SHO!