Two winter - low budget - Café project from central Europe.

[mr.Pink]

In the end of 2018 my GS looked like this. I am going to write the whole story of her and put it here under. As well as Ill keep you posted about the progress which I am getting this winter.

I hope that you enjoy it and write here some technical tips and tricks. I would be glad about anything, since this is my first built.

[mr.Pink]

(My Suzuki GS500 E 95)

It all begun in fall 2017, when I came to visit my brother to his garage and he showed me this Suzuki, which his friend bought for his wife, at the time, and which she refused to ride. And because my brother hates his friend's wife, the bike was in short time sold to me.

(Hoop)
I measured everything carefully and ordered a seat from caferacerseats from UK, while thinking I was ordering something special. (super-expensive – no quality – my fault.) My brother made a project for a hoop and let his colleague to produce it - since his company projects and produce heavy industrial machines (which has been the great-help during the whole project). Meanwhile, I did several hundreds of kilometers during the last days of Czech cold fall to find out what did I actually buy.

(measurement for the new seat)
The first snow of winter 17/18 fall down and I and my brother started working.
We customized a seat a little, cut and welded the sub-frame with heavy struts so the frame will not lose its firmness.


(hoop and seat holder on the bike – still without struts)

After a weekend it looked that the work worth it......
With the seat on the subframe for the first time.

You can compare it with the original.

I got alu-mud-guards from Germany we welded the rear mudguard-holders to the struts.
My brother made a  customized front mudguard holder from the old front-mudguard one.
Which was unbelievable to see. He cold-bent stripe of super strong metal over the tube (using huge hammer), with roughly the same radius and welded it on the top of original mud-guald holder and cut the old one under.


(Front mudguard + new holder)
We changed the turn-signals and add a Chinese tail-light. All with E mark – which is super important in Europe.

(the whole rough built)
However, electronics still does not work. We have to find out, how to re-shuffle the electronic parts of the wire

Wiring
UNFORTUNATELLY, the old 11Ah battery does not fit into the customized sub-frame so I made a new battery box from both - the old battery box and parts of PC power supply. I did not have money for li-on - small one, yet, so I put little 5Ah battery inside. For which I am going to hate myself for whole summer.

(custom batt-box)
On the side of the battery box there is a new flasher for diode turn signals and side stand relay.
My electricity was little f%&ked up, there must be somewhere + on the frame, I was still little afraid of jumping into work like this so I made my friend who does electricity for living did mine on my bike. In the end it was still f%&ked up but about it later.
I had my wheels painted.

Which made a huge difference in the over all look of the bike – when I was putting them on I used new brings.

Meanwhile I got rid off rest of the sub-frame color and rest of useless metal pieces which were there. Which can be written into one sentence but it was work for so many hours.
I put on the under - color


As you can see, we found out the new place for ignition unit – regulator found the new place too – its vertically mounted to the side of the frame in the middle where cold air can reach it.

Rear break reservoir stayed on the original place as well as starter relay


Matt - black spray as the upper-layer.

I got a new exhaust – Nederland's cheap brand Dominator, but they gave you 5 year warranty and you can put in the DB killer which is very important, when you want to travel over Europe. In some states, like Austria or Germnany, they have tough DB limits.
I put on the exhaust wrap too.
We changed the oil and checked the clearance on intake, exhaust and cam chain. We had to change shims on intake but the rest was okay.

(first round is finished – with my girlfriend)

The first round was finished, and the summer season begun – over which I did roughly 15 000 KM – ALLROAD
Over the summer we customized steering, front suspension, headlight, handlebars, cable works, and  a dash-board.
I was researching a lot. We did maintenance of engine several times. So when the snow fall down again this winter. I decided to do it again and most properly.

[qcbaker]

Hey man, your pictures are really massive. Here's a tip regarding big photos:

Large images can be made smaller by adding the width argument to the IMG tag. 800 pixels is a good starting point since most monitors are at least 720p:

Code Select Expand

[img width=800]https://example.com/picture.jpg[/img]

Makes your pics look like this:















Much easier on the eyes.

Anyway, cool build! Hope to see more in the future!