Alright boys here's the scoop...
04 636 B1... From the dealership with a severe knock.
I get greedy and decide to start her up and ride her 30miles to my hardened kawi vet of a mechanic.... 25mi later, at a stop light, motor seizes, and wonderfully heavy billows of light smoke burst from my fairings.
Now this isn't the newbie mistake of the week (I'm getting there).
Buy used motor with 9k (conveniently matching my ODO reading) and commence the turning of wrenches.
10 hours, 100's of S#!T A$$ F%$@'s, and 1 butcher of a first motor drop later, I have a pretty 636 engine on the floor and a new one in the box.
I'm sure you guys are curious, so I'll explain the initial malfunction. Pull apart the motor and I get to find an obliterated valve actually broken and jammed in the head...multiple pieces of piston floating around. My guess, squid before me got her way too hot, perhaps lack of oil. I'll show pics when I get the chance.
Back on the subject, however. I commence to turn wrenches again, and fight my way to a complete bike again. Couple squirts of starter fluid and that huge successful smile can't leave me face. I put her all back together, referring to manual when I get perplexed by kawi's genius or lack there of on occasion.
She starts and runs fine, until I actually hit the highway...
1st is tight up to 9k rpm... starts to slip....
2nd is tight up to 8k rpm...starts to slip...
story continues throughout the gears.
My prognosis... CLUTCH.
Back to the garage where my butchered old motor is scattered about. I find my old clutch, and pull the plates....they look good 8/10, no marks, and plenty of friction left.
Commence the turning of wrenches. Pull out current clutch plates, and to my ever confused self, they're in even better condition 9/10... now I'm confused....but I do notice the four springs are a lot looser than the old clutch (seeing as I ruined numerous allen wrenches in the process). My prognosis, tighten 'em up.
Back to the highway...same issue, and now I'm both confused and furious. I invite my bro's over to sit and talk about our feelings...aka drink our faces off!
Back to the garage... I stare at the beautiful machine wishing I could figure out the problem. I stare at the 100's of pages of kawi drawings...until... lightbulb.
Newbie Mistake of the Week: When reassembling the bike, I put the clutch cable on slightly wrong. In detail: the little black bracket that hold the the clutch cable on the the clutch cover. I had the 2 adjuster nuts on the same side (the side closer to the front of the bike). This didn't allow the cable to be tensioned properly, in this case too tight. The problem wasn't the clutch slipping, it was the clutch never being fully engaged in the first place! I move the cable, adjust the nuts and WA-LAH! Runs like a champ!