So, since I've had this thing sitting in my signature for years now, I figured I may as well share the actual project part of it here.
First day in the garage (back in 2008):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/waybefore.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/waybefore.jpg.html)
After going over the entire thing over winter (basically just cleaning / painting / maintenance):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/1021091505.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/1021091505.jpg.html)
And here it is in its "cafe" trim, parked next to a bone stock GR650 for comparison:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/Sidebyside_zpsnlkt9wdh.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/Sidebyside_zpsnlkt9wdh.jpg.html)
More to come ...
Here's how it sits now:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140623_100405_zpspvc5lpzj.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140623_100405_zpspvc5lpzj.jpg.html)
I've been doing a lot of planning, measuring, purchasing, etc for the past couple years. My GS450 took a good bit of time and money (and now that I have a 2 year old son, there isn't much extra time or money). But now that the little GS is done, I can concentrate back on this project.
Once I get some time in the garage, I'll be taking more pictures and posting updates.
I've read the entire build thread over at DTT multiple times now; back in 1983, I thought the Tempter was one of the ugliest motorcycles I'd ever seen. The GR650X (with wire wheels) wasn't quite as bad. Seeing how you transformed that styling nightmare into a work of art was worth the time it took to read all 67 pages, or whatever the page count is these days.
Post more when you can, your build notes are very educational.
Thank you sir. I can't remember seeing you post over there, what's your screen name?
I'm sorry you had to read thru 67 pages of that thread.......I started a new thread since this will be such a different beast though.
But you're absolutely correct about the bike being ugly. Who the f*** came up with the name Tempter? Haha....
I haven't logged in to DTT for months now Rich, so it's good to see you posting this here... I might get to follow :oops:
All good Pete! I'll try to post the same info here as I do there, but I do forget from time to time.....
First up: the stock foot peg mounts (the white chalk is just a reference for me):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_085819_zps2jfaioy6.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_085819_zps2jfaioy6.jpg.html)
Majority of the mounts are gone, just need to smooth over some edges:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_093725_zps31djhy8x.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_093725_zps31djhy8x.jpg.html)
Stock GR swingarm on the right, made of steel and set up for a drum brake. Swingarm on the left is from an 83 GS750 ES. Almost identical, with a few exceptions: aluminum, factory disc brake, 7/8" longer, and the shock linkage is slightly different. Can't really see it in the picture, but the shock is from a Ducati Monster with the stock Suzuki spring installed (the spring rate on the Ducati shock is too stiff):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_082830_zpsaudurgox.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_082830_zpsaudurgox.jpg.html)
Aluminum swingarm installed:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_094741_zpsgeefhgr5.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_094741_zpsgeefhgr5.jpg.html)
I had a friend who is a professional welder work on the shock linkage to retain the stock ride height. Basically one part of the linkage needs to be 1/8" longer.
Stock GR650 tank which holds a measly 3.4 gallons!
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_094133_zpsftkucdjg.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_094133_zpsftkucdjg.jpg.html)
When I redid the bike before, I put a tank from a GS450 on, which was a little better at 3.8 gallons...... but I don't like stopping for gas that much. So.......
Go big or go home!
(http://i598.photobucket.com/albums/tt70/rmyers104/photobucket-17666-1339015746865.jpg) (http://s598.photobucket.com/user/rmyers104/media/photobucket-17666-1339015746865.jpg.html)
Tank on the left is the 3.8 gallon GS450 tank. On the right is a 5.8 gallon tank from a 1980 GS850.
Problem with the GS850 tank was the width .....so I had to hammer in some knee dents. The red paint is kind of a trial run, but the finish will be similar.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_095028_zpscfth8fxq.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_095028_zpscfth8fxq.jpg.html)
Triple tree from a 1994 RF900, forks from a 2001 Bandit 1200, 43mm clipons from eBay:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_095617_zpsyo2valry.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_095617_zpsyo2valry.jpg.html)
Here's the view from the rear:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_095715_zpsy1mshdtp.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_095715_zpsy1mshdtp.jpg.html)
Fairing bracket from an 86-87 GSXR:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_095803_zps8anum7mw.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_095803_zps8anum7mw.jpg.html)
And the neck with mounts welded on:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_095835_zpspp0w3tvh.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_095835_zpspp0w3tvh.jpg.html)
Bracket mounted up:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_100007_zpsdiezpmok.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_100007_zpsdiezpmok.jpg.html)
From the side:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140624_100020_zpsjnhhy7he.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140624_100020_zpsjnhhy7he.jpg.html)
Upper fairing mount welded to the back bone of the frame (I'll make a Y shape support that connects this to the mirror mounts):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140625_082846_zpsjwxxtppm.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140625_082846_zpsjwxxtppm.jpg.html)
Just an idea of how everything is fitting together so far:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140625_083249_zpshuh1axhs.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140625_083249_zpshuh1axhs.jpg.html)
And here's the 3/4 endurance fairing from Airtech loosely mounted up (it doesn't photograph well since it is SO bright and my garage is so dark:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140625_083113_zpsfuvfu37w.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140625_083113_zpsfuvfu37w.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140625_083455_zpsohai009k.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140625_083455_zpsohai009k.jpg.html)
Here are the headlights I'm using:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140626_090639_zpsfeomgm2i.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140626_090639_zpsfeomgm2i.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140626_090627_zpspkfwhbes.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140626_090627_zpspkfwhbes.jpg.html)
The one on the right is a 4.25" diameter H4 light from Airtech, and the one on the left is an old Derbi moped light that is about 5" diameter. The reason the Derbi light has been hacked open is to fit one of these
http://stores.advmonster.com/led-lights/
I'm looking at either the model 50 or model 60, and it will be hooked up to a relay coming from the high beam.
Made some VERY rough mounts for the headlights. I wanted to leave enough steel so I can adjust them for ride height.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140630_033041_zpsz0fhzomi.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140630_033041_zpsz0fhzomi.jpg.html)
Behind the fairing:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140630_032835_zpsblkemlfs.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140630_032835_zpsblkemlfs.jpg.html)
And messing with electricity :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140630_011244_zpsf0lho7z6.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140630_011244_zpsf0lho7z6.jpg.html)
Love your work Rich, looking good! What are you doing for a dash/speedo/etc.? I can't remember what you had on there before...
Cheers Pete! I had an Acewell before, but I probably won't be using it again. Only because I have a LOT of space for an instrument cluster and the Acewell is so small. So it's still up in the air for now...... I'd like to have the same features as stock (fuel gauge, tranny gear display, etc) but I don't want to use stock looking gauges or some cheapo unit from China. Plenty of time before I get to that though.
Ah ok cool... they do have the larger Acewells that have all those functions though... food for thought? But yes plenty of room in there now!
Keep the updates coming Rich; I can't get enough of this build. I think most of the old-timers can really appreciate the work you put in on this ugly duckling; vintage DNA at work... as young as you are, you sure seem to appreciate and respect the classics more than the modern "tupperware techno-monsters", to steal a phrase from years gone by.
This and your GS450 both stand out in a crowd of stuff I would only ride at night...
Ha! Thanks man. I wouldn't say I'm all that young though...... I'm older than this GR650, and my GS450 is actually slightly older than me.
But anyways, there are some pretty big updates coming. I have a couple parts coming in the mail, and I'm saving up for a gas tank for my welder.....
Your 450 is older than you? Damn... I'm 8 years older than my 450...
Sent from my iPhone using Tapatalk
Same model year, but it was "manufactured" before I was. :thumb:
Ah ok! Glad I'm going by manufacture date too... model year makes it 9 years younger :o
So this showed up today:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140703_182053_zpsnaac0plw.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140703_182053_zpsnaac0plw.jpg.html)
Bandit 1200 wheel with a 120/70-17" tire. I need to check the rotors to see if I can use them, and the bearings & tire will be replaced before I ride on them. But I can at least mock up some other stuff now.
The rear wheel came in today, and I got both of them mounted up:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140705_133016_zpsui9d5vbg.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140705_133016_zpsui9d5vbg.jpg.html)
It's from a 2001 Katana 750, and has a worn 150/70-17 on it. Now I just need to figure out the spacing for everything. The front wheel is odd - when using the supposed proper axle spacers, the wheel is offset about 6mm in the forks. And the rear wheel will need some mixed and matched parts to get it to fit.
Lowered the bike down onto the wheels, and took the fairing off (much better picture quality without it....):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140705_225034_zps6yymktro.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140705_225034_zps6yymktro.jpg.html)
Something odd I noticed about Bandit forks - they don't have any kind of brace. I guess the stock fender is just solid plastic. And the fender mounts are like older bikes, except really high up (above the tire, actually):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140707_232023_zpsjatmis3w.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140707_232023_zpsjatmis3w.jpg.html)
I got some 6mm coupler nuts and stainless allen head bolts, and used a GS500 brace as a template to make a cardboard template:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140708_005250_zpsydpatbpm.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140708_005250_zpsydpatbpm.jpg.html)
Got some .100" steel plate and cut it using the cardboard template. With the coupler nuts tight in the forks, I tack welded the plate to the nuts:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140707_232052_zpsnakebwz6.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140707_232052_zpsnakebwz6.jpg.html)
And here it is with some better welds and bolted in place:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140708_005308_zps9p7kl1bb.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140708_005308_zps9p7kl1bb.jpg.html)
While I was in the garage, I made some tabs for the lower fairing mounts. These are directly in front of the engine, and slightly below the header ports:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140708_040403_zps1dkrwurj.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140708_040403_zps1dkrwurj.jpg.html)
Worked on the upper fairing mount a little too. I cut and drilled an "L" shaped bracket to bolt to the mount on the backbone, and got a 3/8" solid rod. With some more cutting & welding, the rod is attached to the "L" bracket.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140708_040412_zps4v5oqkzl.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140708_040412_zps4v5oqkzl.jpg.html)
After I took that pic, I heated up and bent the rod towards the front of the bike......but didn't take a pic, sorry.
Good stuff Rich! The GR will be a different beast entirely once you're done!
Sent from my iPhone using Tapatalk
Thanks Pete! It's been parked for so long now, it'll be great to get it on the road at all. I'm hoping on having it "rideable" but unsafe (to my standards) before winter, and back to 100% come next spring.
Nice Rich! At least you've got that great little 450 in the meantime :)
Sent from my iPhone using Tapatalk
Good ol' 450. Dependable little bugger.
So here's where I'm at currently with the upper mount. I bent it forward a little and fitted the fairing to see where it needs to go. Doesn't look like much now, but it's progress......
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140710_083020_zpsmvuuqy8k.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140710_083020_zpsmvuuqy8k.jpg.html)
Couple other parts showed up today so I tossed this together before leaving for work. GS500 sprocket carrier (w/ old 520 sprocket), 01 Katana caliper mount, GS500 brake caliper, and an 01 caliper torque arm. I can't say the wheel is perfectly centered in the swingarm yet, but just eyeballing it it looks pretty close......
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140711_181912_zpsmh5fgzal.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140711_181912_zpsmh5fgzal.jpg.html)
I've been working a bunch of overtime recently, but got last night off unexpectedly. Good chance to work in the garage all night! Got a little more done on the upper fairing mount:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140715_152949_zpsbxdubmik.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140715_152949_zpsbxdubmik.jpg.html)
The solid rod coming up from the frame is 3/8" diameter, and the cross pipe has a 1/2" OD, 3/8" ID. So I drilled a 3/8" hole in the side of the pipe, slid it on the rod, and threw in some tack welds. Then cut a T shaped gusset and welded it in for support.
I'll be mounting an auxiliary light to the old horn mount, but wanted to check how well it will fit. Once I saw how much space I had, I welded a mounting bracket under the light for the R/R:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140715_152932_zpsne8xm3ep.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140715_152932_zpsne8xm3ep.jpg.html)
And it was brought up elsewhere that my fork brace may cause the forks to bind. Ben2go mentioned popping the tops off the forks and checking the travel of the forks:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140715_003845_zpsc6omv8id.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140715_003845_zpsc6omv8id.jpg.html)
Originally, I didn't use the ratchet strap to lift the wheel / fork lowers, I just slid them up by hand. But when I did that, some washers popped out of the forks, so I needed the strap to hold the lower assembly up to put the washers back.
Excellent work Rich! Man I gotta say I'm missing not having a project to get stuck into at the moment...
Sent from my iPhone using Tapatalk
Thanks Pete! It's nice to have something to tinker with in my spare time. Hopefully you can your projects back underway soon.....
Yup very true! And yeah very keen to get my hands dirty again! Doing the relay mod'd on the 450 was something but it's not quite the same...
Sent from my iPhone using Tapatalk
My Tokico 6 pots showed up the other day:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140721_131439_zpsozpyzaxh.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140721_131439_zpsozpyzaxh.jpg.html)
But I realized I have an issue with my front wheel spacing now. I used a triple tree from an RF900, and forks from a second generation Bandit (the triple tree from an RF and first gen B12 is identical except for stem length btw....). The only thing I can think of is that the fork spacing changed from the first and second generation Bandits. Which means I'm looking for a new triple tree and top clamp, and may have to do a stem swap. We'll see......
Finally bought a gas tank for my welder. No more dirty flux core welds!
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140724_042618_zps3euhuf7f.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140724_042618_zps3euhuf7f.jpg.html)
While I'm thinking about it, I installed a threaded insert into the top fairing mount. They are 6mm coupler nuts with the hex head ground down enough to slide into the tube. Once they slid in, I drilled a 1/4" hole on each side and welded the coupler nuts in place (sorry for the extreme close up pic):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140724_042554_zpshgx5jl2h.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140724_042554_zpshgx5jl2h.jpg.html)
One of the biggest obstacles with my GR was the shape of the frame under the seat. Suzuki dropped the frame down to make room for a huge seat, and that interferes with anything I want to do under the seat. With a little bit of planning, this happened:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140723_235146_zpsqsbw8jcb.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140723_235146_zpsqsbw8jcb.jpg.html)
And here's where everything is sitting at now. The extensions are 1" diameter 16g DOM tubing, with 2" long slugs welded in for strength. I need some more tubing to do the rear loop (around the tail light) and then I can cut out and replace the seat rails:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140724_042421_zpsglst52kc.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140724_042421_zpsglst52kc.jpg.html)
So this showed up today:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140725_164811_zps1jsdjj7y.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140725_164811_zps1jsdjj7y.jpg.html)
From a Bandit 1250 (same as a second generation Bandit 1200). I looked it over before heading to work, and it definitely has a wider fork spacing than my current triple...... by about 5mm, which is about what I shaved off the axle spacers to get the wheel centered. I didn't get a chance to accurately measure the stem lengths, but throwing a scale on each one shows about an inch difference.
Awesome stuff Rich! 6 pot front brakes hey? Nice! One day I will be able to weld like that... maybe... :D
Cheers Pete! I'm excited about having the ability to weld.....it opens up a lot of possibilities, that's for sure. The cost of getting started though......ouch!
So I've been really preoccupied lately, but I did get some garage time last night. First thing first, the motor is out of the frame:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140801_053117_zpspgohuynf.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140801_053117_zpspgohuynf.jpg.html)
The seat frame is still in the works along with the front end, but I'm waiting for parts & material to do both. But here are the lower fairing mounts:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140801_053128_zpsbrnz834n.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140801_053128_zpsbrnz834n.jpg.html)
I made arms that bolt to the frame tabs I welded on a couple weeks ago, and tabs that bolt to the frame. The "cross tube" is just a tube with more 6mm couple nuts welded in. With that tube in place, any pressure transferred from the fairing will go to that tube (and not the tabs welded to the frame). That's the plan, anyway.....
And the upper fairing / mirror mounts:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140801_053139_zpssy21smqj.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140801_053139_zpssy21smqj.jpg.html)
All the nuts & bolts pictured are just ones I had laying around. So they'll get replaced in time. And all the edges are a little bit rough for now, but it's good to have the framework in place.
Just getting better and better Rich :icon_mrgreen: :woohoo:
Thanks Pete! New steering stem showed up today, and it's good news - it looks like everything will fit perfectly. Here's a comparison of the two (Bandit 1250 on the left, 98-06 Katana on the right):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140805_210016_zpsw08upixg.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140805_210016_zpsw08upixg.jpg.html)
The new stem is from a 98-06 Katana 600 / 750. The reason for the 98-06 stem is because the upper portion that sticks thru the top clamp is identical to the Bandit, so there's no messing around with that. And the length of the Katana stem is perfect for the GR frame. Some time over the next couple days I'll be pressing the Kat stem into the Bandit lower.
Pressed out and swapped stems yesterday:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140806_235151_zpsdpmfsnh0.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140806_235151_zpsdpmfsnh0.jpg.html)
Happy to say everything is fitting together nicely now.
Nice Rich! A subtle change can make a big difference... especially for fork spacing!!!
Finally getting some time back in the garage. Most of the stuff I've been up to isn't really picture worthy, but I do want to share this..... somebody asked how I know the rear wheel is lined up with the front. Here's a link that explains it better than I can:
http://classicmotorcycles.about.com/od/technicaltips/ss/Classic-Motorcycle-Wheel-Alignment.htm
And some pictures of me doing it - look close and you'll see the 8# fishing line:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140817_030145_zpsabm7lcyo.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140817_030145_zpsabm7lcyo.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140817_030210_zpstllprwb1.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140817_030210_zpstllprwb1.jpg.html)
I installed the fairing mirrors, and welded in some new steering stops, but didn't take pictures specifically for them. More updates soon....
Time for an update! My ADVMonster Model 50 showed up:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140830_221902_zpsy2ubnjr8.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140830_221902_zpsy2ubnjr8.jpg.html)
Here it is crammed into the Derbi headlight (on top in the pic, bottom light is an H4):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140902_045005_zpsmf3jjri6.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140902_045005_zpsmf3jjri6.jpg.html)
I wasn't able to take a picture of the light output, but I will eventually.
Here's what I've been working on so much recently.... the seat frame. Just a reminder where it was stalled at:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140821_231420_zpsryvnat0l.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140821_231420_zpsryvnat0l.jpg.html)
Notice the dropped section right behind the gas tank mount. I cut that section out, bent the rails until they pointed straight back, and made some slugs for new rails:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140902_011003_zpsgqhffjl_edit_1409682031404_zpstt9zqju4.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140902_011003_zpsgqhffjl_edit_1409682031404_zpstt9zqju4.jpg.html)
Bent up some new tubing, and welded it all together, along with a rear loop.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140902_044948_zpsle8g1ea6.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140902_044948_zpsle8g1ea6.jpg.html)
Here's a comparison of the new rails (bare steel) compared to the original (painted black):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140902_044926_zpsvybyq1mi.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140902_044926_zpsvybyq1mi.jpg.html)
Once I woke up this afternoon, I rolled the bike outside for a decent picture:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140902_170350_zpsrwg9nx7e.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140902_170350_zpsrwg9nx7e.jpg.html)
I'll be adding a couple braces soon, but the basic framework is done.
So I made the rough cuts for the headlights.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140908_152516_zpsperbccst.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140908_152516_zpsperbccst.jpg.html)
And jumped the lights because I guess I like to blind myself....
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140908_152448_zpssxoxi68j.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140908_152448_zpssxoxi68j.jpg.html)
Wow this is great work!!! I love the headlights... can't wait to see more :laugh:
Great build. Subscribed. :thumb:
Thanks Showbiz and Jar. I know it looks like parts being cobbled together at the moment, but that's how all these projects start out.....
You're absolutely right ! This IS how projects come together. From the pics in your first post it looks like you did a nice job on the cafe conversion, and now to this ? Amazing ! It's how you make your bike, " your bike". Welding and fabrication doesn't come easy. Anyone can slap prefab parts on a chassis but you chose the one off route. I love the progress. Keep up the great work! :thumb:
Quote from: Big Rich on September 09, 2014, 07:15:39 AM
Thanks Showbiz and Jar. I know it looks like parts being cobbled together at the moment, but that's how all these projects start out.....
Heck yeah, agreed!! The truly custom stuff that people do... showing imagination and quality work... will always catch my eye :icon_mrgreen:
When I was a kid I would go to car and bike shows. I would take pictures of everything. Nowadays it takes custom work or some type of wow factor for me to pull my camera out. Now I don't want anyone to take that the wrong way. I like anything that sets someone's car or bike apart from the rest in one way or another.
Quote from: ShowBizWolf on September 09, 2014, 01:05:19 PM
Heck yeah, agreed!! The truly custom stuff that people do... showing imagination and quality work... will always catch my eye :icon_mrgreen:
Well said. I feel exactly the same :thumb:
I was messing around last night and rolled the bike out to check out my lighting. I know every light is bright as heck in a picture, but here's the high beam from about 50' away:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140910_025529_zpsze83ctdm.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140910_025529_zpsze83ctdm.jpg.html)
And I noticed the seat frame wasn't perfectly lined up so I spent some time grinding, banging, welding it back together. I added some smaller tubes for cross braces between the lower rails and the seat rails. Here's the skeleton so far:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140910_032216_zpswyclxgc2.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140910_032216_zpswyclxgc2.jpg.html)
Ya know, I was at a bike show pretty recently. I can appreciate any custom work, that's for sure, but there is some stuff you see and it just makes you wonder sometimes..... I talked to some younger guys at the show - in college or just out, no money, etc - but they loved working on their own scoot to the best of their ability (and financial means). And I dig that. There was a few older guys that do some pretty rad work, and they've been doing it for a long time. What bothers me is when somebody intentionally makes a bike unsafe to achieve a certain "look". As if riding a cycle isn't dangerous enough.....
Funny little story though: there was a group of 5 or 6 guys that all had newer Triumph Thruxtons. They all had the old "Rocker" theme going on too - slicked back hair, misc patches on their jackets, etc, but the bikes and clothing all looked really new. When somebody would cruise past on a Harley, one of these guys would snicker and say something about "buying a lifestyle"...... made me laugh a little when I heard that.
First off nice welds. Are you a welder by trade ? Second I agree with safely modifying a bike ...
I'm definitely LOL at the guys who make goofy comments about " buying the lifestyle".
Quote from: Big Rich on September 10, 2014, 06:04:06 PM
Ya know, I was at a bike show pretty recently. I can appreciate any custom work, that's for sure, but there is some stuff you see and it just makes you wonder sometimes..... I talked to some younger guys at the show - in college or just out, no money, etc - but they loved working on their own scoot to the best of their ability (and financial means). And I dig that. There was a few older guys that do some pretty rad work, and they've been doing it for a long time. What bothers me is when somebody intentionally makes a bike unsafe to achieve a certain "look". As if riding a cycle isn't dangerous enough.....
Funny little story though: there was a group of 5 or 6 guys that all had newer Triumph Thruxtons. They all had the old "Rocker" theme going on too - slicked back hair, misc patches on their jackets, etc, but the bikes and clothing all looked really new. When somebody would cruise past on a Harley, one of these guys would snicker and say something about "buying a lifestyle"...... made me laugh a little when I heard that.
Welder? Oh no, not at all. I just started with a stick welder about a year ago and those welds pictured above were made with a Harbor Freight mig setup. I try to weld as much as possible though, and I'm definitely not afraid to grind a weld off and do of again.
By trade I'm a machinist - but not the useful kind. I work with high production / loose tolerance rough work.
Thanks for the compliment though Jar!
Ok, so a good bit has been changed since last time:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140918_135544_zps0m1fnkq3.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140918_135544_zps0m1fnkq3.jpg.html)
The most obvious is that I cut off the rear frame hoop. For me to use the taillight that I want, the loop had to be so big..... TOO big. Off to the scrap bucket it went. I welded up the seat pan mount, along with the rear gas tank mount. I also fabbed up some seat frame uprights - the left side is very visible in this pic, and it looks huge. But once the gas tank is mounted they are much less obtrusive. Also ordered some plastic seat tail sections to use as molds for a fiberglass seat:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140918_154002_zpsxclf0exd.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140918_154002_zpsxclf0exd.jpg.html)
Very nice Rich! Sorry haven't looked in for a while so nice to see her coming along!
Sent from my iPhone using Tapatalk
No apologies needed, Pete! I understand you're a busy guy. Glad you checked in though!
Always keen to see what you're up to Rich!
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Started messing around with rearsets :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140925_150704_zpswt4ewoov.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140925_150704_zpswt4ewoov.jpg.html)
I started out with cardboard, then switched to ABS plastic so I could get a better idea of where everything needs to be. Aluminum is next......
While I'm waiting though, I started getting locations for the electrical stuff squared away:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140926_020433_zpsgcibtlzm.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140926_020433_zpsgcibtlzm.jpg.html)
In the pic, you'll see the starter relay in between the gas tank rubber pad & rear tank mount. In front of the tank pad is the fuse box and ignitor.
And I welded in a cross brace for the rear of the seat frame:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140926_020454_zpsjknzlgxq.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140926_020454_zpsjknzlgxq.jpg.html)
Ignore the chrome fender - I just used it as a reference while welding. And here's the gas tank mounted over top of the electric bits:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20140926_043425_zpsx2lmcbel.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20140926_043425_zpsx2lmcbel.jpg.html)
Ahhhh this is so cool... I love it. That last pic looks awesome, no doubt.
Aluminum sheet came in. 12"*12"*1/4" thick:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141001_225334_zpssfc96pql.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141001_225334_zpssfc96pql.jpg.html)
Cardboard template:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141001_225355_zpsqjv10ero.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141001_225355_zpsqjv10ero.jpg.html)
Generic shape cut out and drilled 2 of the 3 mounting holes:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141002_214616_zpseno12hfr.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141002_214616_zpseno12hfr.jpg.html)
Two of the 3 holes drilled for each rearset, checking fitment.....
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141002_224443_zpsmftgop8x.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141002_224443_zpsmftgop8x.jpg.html)
All mounting holes drilled out and cut some excess material from the inner area:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141013_095324_zps8qy0bdxr.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141013_095324_zps8qy0bdxr.jpg.html)
Now that the rearset plates are fitted up, it was time to make the seat frame removable :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141005_085047_zpsj2kloj8q.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141005_085047_zpsj2kloj8q.jpg.html)
No going back now....
And the seat frame:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141005_084906_zpshsbspguw.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141005_084906_zpshsbspguw.jpg.html)
I am loving it Big Rich... that looks realllyyy cool! Tell me, do you have a pic of the bike from the side with those rearsets on? I wanna see them in relation to where the seat will be, etc. :D
I use aluminum for a lot of the custom stuff that I do, mainly because it won't rust!! I hate rust >:( Did you use it cuz it is lighter?
I should have modded the frame etc etc to mine before I powdercoated it. In fact its coated a beautiful silver with mica flecks and clear coated over. Looks miles deep with simmery flecks. Worse yet, I coated the tank is flat blue. Sorta making a negative bike. What flat in normal bikes is shiny and what's shiny is flat in that one.
Anyway I am itching it hack it up now. The cafe world is calling.
Cool.
buddha.
Awesome stuff as always Rich! That alu should be plenty thick enough I reckon... my fork "brace"/front guard mount is made from 2.5mm alu and seems to be holding up well to that torture after nearly three years...
Here ya go Showbiz:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141016_074804_zpsujmxcaps.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141016_074804_zpsujmxcaps.jpg.html)
The seat plastic is just resting on the frame, and it will be altered a good bit before it's finished (moved down / shortened / moved back). I used the aluminum because it's lighter....... and because it is SO much easier to work with than steel. I work in a machine shop for a living working with steel every day, so aluminum is a good break from the norm!
Buddha, good to have you along. I've never seen your GR (or the GS500 with a GR motor transplanted in it). Hint, hint.....
And Pete: I'm sure the aluminum plate will do the job. My butt is depending on it! Haha.....
Wow does that ever look awesome!!! THANKS for the special pic :-D :-D :-D
Hahaha yep Rich I'm sure it will be fine! I agree with aluminium vs. steel too... not exactly a machinist myself but having played with both now I can only agree. The only issue I've had with aluminium is vibration and thinner pieces... tends to break quite quickly!
Pete, that reminds me - remember my plastic chain guard busted and we had discussed other options? Since I was running that GS450 L chain guard I just cut the entire rear mount off of it and used some rivets to attach it to the GS450 E/S chain guard. No more huge chrome guard on my swingarm!
But the GR is going to be sitting for a couple weeks, so no major updates. I will be stockpiling some parts in the meantime though. I need to replace a section of roof on my house, along with soffit / fascia / gutters / etc.
Yay.
Hey Big_rich - Did you get rid of that crazy contraption rear shock linkage and whatever its called.
I wanna go to a proper swingarm and shock setup - like shudder shudder ... a GS.
What you do in that part ?
Cool.
Buddha.
Aaaah good thinkin' Rich! I have a bit of galvanised steel rivetted to my plastic guard to hold the mount in place where it broke... ugly but serviceable.
Buddha, I didn't change up the rear linkage too much at all really. To fit the Ducati Monster shock in the GS750ES swingarm I did have to modify one part of the entire linkage to keep the stock ride height, but that's it. I remember reading a review about the GR650 and they mentioned the weight of the bike......and specifically said the experimental shock setup (at the time anyway) surely added a lot of unnecessary weight.
I'll admit: I don't have enough of a comprehension of motorcycle suspension to try and "start from scratch". Heck, even what I'm doing now can easily be reversed back to stock if need be.
One i had was silver and blue if my memory recalls correctly. Cant wait to see her finished. Iirc, buddha i think had a gr prokect @one time
Aaron, if it was silver & blue you had the "upgraded" model. Two tone paint, front parking light, mag wheels, and air assisted front forks were the only differences. The GR is a great bike.....once it is modified. But maybe I'm a little impartial.
I've gotta look at it in closer detail. I am hoping to keep the stock SA and wheels and FE etc etc.
In fact the 2 things I want to get rid of - the stupid shock linake garbage, and that godawful seat, sissy bar and other crap that is connected to that seat frame.
IMHO the bike will look awful with those trailer fenders and all the other standard "Bobber" junk.
Its got to have side covers, and air box and in effect I want to fit a rear fender off another bike - just not the original rear fender. Only the last ft of the tail section has to be modded.
The shock linkage - yea all that crap has to go, a simple GSXR shock is what it needs.
I've gotta look at it and design it and see.
Cool.
Buddha.
Quote from: yamahonkawazuki on October 30, 2014, 06:11:36 PM
One i had was silver and blue if my memory recalls correctly. Cant wait to see her finished. Iirc, buddha i think had a gr prokect @one time
There are 2 or more. One is the GS frame GR motor bastage. The other is the GR that wants to be a better GR. Like a proper bench seat clean GR.
Cool.
Buddha.
Ok, so my last update was that I made the seat frame detachable. I added a mount for the rear brake reservoir, some tube bracing for the rear section, and a mount for the keyed seat release (which isn't shown in this picture):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141021_225308_zpsrz1msung.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141021_225308_zpsrz1msung.jpg.html)
I plan on using a steering stabilizer from a GSXR, but I wanted to make sure it would clear the engine if it was side mounted. Here's the process of reinstalling the engine by pictures:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141104_234943_zps6rp1gjlo.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141104_234943_zps6rp1gjlo.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141105_001015_zpssyrczcz1.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141105_001015_zpssyrczcz1.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141105_004740_zpstbnvjqii.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141105_004740_zpstbnvjqii.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141105_010520_zpsbwwxbqxw.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141105_010520_zpsbwwxbqxw.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141105_011004_zpst9yfrrhc.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141105_011004_zpst9yfrrhc.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141105_011912_zpsaqqja7dv.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141105_011912_zpsaqqja7dv.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141105_012617_zpshxo8wf8f.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141105_012617_zpshxo8wf8f.jpg.html)
After all that, I realized the GSXR damper didn't have enough travel to be side mounted. Bastard. So I figured it'll need to be mounted up front. Still need to weld the mount to the front of the frame:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141105_150537_zpslnkkepsf.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141105_150537_zpslnkkepsf.jpg.html)
That's it for now!
Awesome update! MAN am I ever JEALOUS of that garage space... I would LOVE to take out a loan and build another bay onto my garage... someday!!!
Ha! Thanks Biz. When it didn't have a bunch of junk in it, I could fit 4 normal sized cars inside. For a couple years I had a 16' boat (w/ trailer of course) and my Jeep Wrangler parked on one side. Definitely a strong selling point of the house.....
I thought I'll put a few pics of my frame, before I hack it up.
(https://lh4.googleusercontent.com/-MANUzzcKPtE/VFvGjuO-ouI/AAAAAAAACLk/FUWGooe75X8/s2048/IMG_5322.JPG)
(https://lh6.googleusercontent.com/-a3AXOi09UjU/VFvGjz7zeUI/AAAAAAAACLs/HRCgxFQVhWM/s2048/IMG_5323.JPG)
(https://lh5.googleusercontent.com/-jut1lOyC5rU/VFvGkkbzx7I/AAAAAAAACLw/oPBKEfg9qBU/s2048/IMG_5324.JPG)
Its silver with tiny flecks of blue. I cant even get that color anymore. I am hoping to mod it such that its not needing to be welded to, so It dont hahve to be coated again.
Cool.
Buddha.
that color is bad-ass!
Had a friend who acquired some old spray paint from the 70's. half of it still was usable. almost that EXACT color/flake was one of the can's.. I wish they still sold rattle cans with flake...
Walker, check out Duplicolor Metal Specks. Maybe not 70's cool, but cool nonetheless.
Buddha, I double tapped my phone and zoomed in on your paint.....it reminds me of something you would see in outer space! You have the Big Bang painted on your GR frame.
Quote from: Big Rich on November 06, 2014, 11:20:06 PM
Walker, check out Duplicolor Metal Specks. Maybe not 70's cool, but cool nonetheless.
Buddha, I double tapped my phone and zoomed in on your paint.....it reminds me of something you would see in outer space! You have the Big Bang painted on your GR frame.
i've tried that metal specks stuff, It just looks like a fairy exploded into your paint.. its TO much specks. I like the smaller/more spaced out specks like buddha's! glad I recently made a friend with a paint shop..! all I gotta do is pay for the paint. if I spray it myself! :woohoo: cheap!
Servus Big Rich,
go with me next week going with a 650 GR framework. However, it is not used the 650s Engine , but a racing engine based on the GS 500.
To be quite deep and quite long.
Thanks for the Inspiration :cheers:
Quote from: Jim Knopf on November 07, 2014, 08:27:49 AM
go with me next week going with a 650 GR framework. However, it is not used the 650s Engine , but a racing engine based on the GS 500.
To be quite deep and quite long.
Thanks for the Inspiration :cheers:
ooh ahh :bowdown:
I like the seat and the rear fender of this one. The seat has too many ribs. Its ribbed for my pleasure ... Y'know like Chuck Norris who wears the ribbed condom inside out ... cos all the pleasure is for him ... I am hoping to have a smooth seat in about that size/shape.
http://garageprojectmotorcycles.tumblr.com/post/34486039136/wenbangers-gr650
But the bed pan under the seat (presumably holding the battery and electricals etc) is a non starter with me.
The inner fender has to be stock, and the side covers and the airbox have to be on and unmangled.
I'm ambivalent on that tail light. Something from a newer HD with a tombstone look would be better - but we can get to it when I get that far.
But a decent starting point I think.
Cool.
Buddha.
Quote from: cbrfxr67 on November 07, 2014, 11:08:22 AM
Quote from: Jim Knopf on November 07, 2014, 08:27:49 AM
go with me next week going with a 650 GR framework. However, it is not used the 650s Engine , but a racing engine based on the GS 500.
To be quite deep and quite long.
Thanks for the Inspiration :cheers:
ooh ahh :bowdown:
You're not kidding!
Jim, I'll be waiting anxiously to see what you come up with (as always). I'm honored to mentioned as inspiration.
Small update - got the mount welded to the frame for the steering stabilizer:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141111_215613_zpsep5uigmj.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141111_215613_zpsep5uigmj.jpg.html)
Then spent the rest of the night pulling the motor out and grinding welds. Yay.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141113_045155_zpsdzhqlqhz.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141113_045155_zpsdzhqlqhz.jpg.html)
There are no small updates my friend.
Only small updaters ... LOL. Hey you already got Big in your handle, so its not you.
Cool.
Buddha.
Haha agreed !!
Hey do you like that Lionshead brew? I been thinking of getting a case (I try new beers all the time) and haven't found anybody to ask that tried it.
:cheers:
Ha! I like to bring more to the table than 6 hours of grinding though.....
Lion's Head isn't bad for the price. I think for a couple $ more you can get Miller light. Funny thing about the Lion's Head bottles: there are little picture puzzles on the under side of the lid. The first couple are easy when you're sober.....
Haha cool! Thanks for the info... will hafta try it. Every time I buy a case of something I haven't had before, I save one can out of it... have quite a few different cans by now ;)
So I've been pretty busy with other stuff lately and haven't had much time to work on the old GR. And most of the stuff I've been doing wasn't very picture worthy.... but I've been concentrating on the seat mostly. Cut the plastic "wings" off the GS550E seat, made a plastic seat pan using the stock keyed release, etc:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150102_085018_zpsualz0tyx.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150102_085018_zpsualz0tyx.jpg.html)
And the mount for the taillight :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20141231_024442_zps8uzesdfe.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20141231_024442_zps8uzesdfe.jpg.html)
This plate will be independent of the seat pan, so it needs to be completed before I can actually start any fiberglass work.
And some minor work on the front end:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150108_031351_zpseijvqz3i.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150108_031351_zpseijvqz3i.jpg.html)
Bandit fender needs proper bolts, and the stainless lines are obviously WAY too long. But it's still progress....
Man i miss my tempter lol
Great stuff Rich! Always nice to see progress on the GR :thumb:
I agree. Any progress is good progress. Keep up the good work.
Finally, an update! I've been busy with other stuff but I did get to work on the seat some more. The last time I messed with fiberglass was back before the internet was around, so I'm learning as I go. First thing I learned: fiberglass mat pretty much sucks to work with. What a mess..... but here's where it sits at the moment:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150508_014952_zpsnzenmd6h.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150508_014952_zpsnzenmd6h.jpg.html)
Updates will be slow as usual, but hopefully more steady now.
Awesome!!! :D I am excited for the updates... I love working with fiberglass cloth and mat but yes the mat can be very messy >:(
Good to see some progress Rich!!
The fibreglass is messy but made it so much easier getting my tail piece in the right shape. If I tried that with steel or aluminium I would've failed as I just don't have the tools for that sort of work.
I have no doubt I will be doing more fibreglass work down the track on other projects but that's fine with me. Just keep it off your skin and you'll be fine...
Thanks folks. Believe me Pete, after getting Aircraft paint stripper on my skin I don't mess around with inadequate skin protection. I couldn't imagine trying to get hardened fiberglass resin off my arm hair or something.... yikes!
Even just the bare matting itches like crazy if you're not careful...
Any updates ya got for us Big Rich? Hope you are getting along ok with that fiberglass!! OH and how is that jacket treatin' ya? I hope good :D
I love it!! nice job
Will follow this one.
Updates? Not anything really worth posting.... I got some fiberglass on my arm that itches like crazy - does that count? Haha..... but I'm still chugging away when I get the chance.
Showbiz, I've ridden to work every day (except two) since the first of March, wearing that jacket. So yes, it is definitely getting plenty of use!
That makes me very happy :D I owned that jacket for almost 3 years and you've already worn it more than I did. I am so glad it is getting used and enjoyed now.
And I hear ya about the itch... it was SO HOT yesterday and I had my car up on the lift, working overhead with fiberglass, in a tanktop haha... my shoulders itch here and there but oh well, part of the fun! :icon_razz:
Small update on the seat: I ended up putting a single layer of cloth on the underside of the seat (and also glasses in the plastic pan to attach the seat to the frame). Once that was cured, I started sanding off all the high spots & bubbles from the top layer.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150605_145444_zpsieabpvvh.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150605_145444_zpsieabpvvh.jpg.html)
I started putting on more cloth & resin on top of the sanded surface, but ran out of brushes..... Since I was in the garage though, I started sandblasting and powder coating some small brackets and other parts - and I didn't take pictures of them yet.
Good to see some more progress Rich, can't wait to see that seat take shape! Should turn out nice I reckon :thumb:
New stainless brake lines all around!
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150613_142544_zps1uz3ppkm.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150613_142544_zps1uz3ppkm.jpg.html)
Sorry about the metal tubing laying around - I'll get to that later on.... and some of the stuff I powder coated: headlight / fairing mount, rear brake arm, and lower fairing mounts:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150613_142906_zpsrnil5egp.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150613_142906_zpsrnil5egp.jpg.html)
Good stuff Rich! Love the stainless lines, they make such a big difference!
They certainly do! After I double checked that they fit properly, I started thinking about my progress on this bike lately. Basically I was working on the seat for a while and couldn't help thinking about how much other stuff was laying around "half done". So I turned my attention away from the fiberglass seat for a while. First up was the swingarm bearings:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150615_131945_zpsea4l4jra.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150615_131945_zpsea4l4jra.jpg.html)
When I bought this swingarm, I noticed the bearings were dry and "notchy". And to fit the swinger to the GR frame I had to get new end caps / washers as well. And a matching chain guard from the same bike (GS700E):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150615_140208_zps9waamxvs.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150615_140208_zps9waamxvs.jpg.html)
The eBay seller had used a white paint marker to identify the bike it came from, so that needed cleaned off. That was when I saw the dried battery acid (?) on the plastic.... oh well. I had some plastic paint to give it a fresh coat of black anyway. Didn't get a picture of that though....
Onto the frame - for the time being I decided a crappy rattle can job will do for the frame. Why, you might ask? Because eventually I plan on getting it powder coated but I'm sure somewhere down the road I will need to modify (grind / weld) something on the frame. No point of ruining a good powder job. And when I get everything sorted, I'm out $5 in paint and some steering stem bearings (which I have extras to my surprise). Here is the frame after getting hit with black appliance epoxy:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150617_024234_zpss0fdohmu.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150617_024234_zpss0fdohmu.jpg.html)
Last picture for the night. Got the front end reinstalled, along with the swingarm. Today I pulled the frame down and installed the wheels just so I can roll it around the garage.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150617_035352_zps52j7h02j.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150617_035352_zps52j7h02j.jpg.html)
So, back to the chain guard.... here it is painted and barely bolted up to the swinger (since it's coming off again for the rest of the rear wheel stuff):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150618_095447_zpsgshthmhz.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150618_095447_zpsgshthmhz.jpg.html)
And found a good deal on a GSXR left hand control that wasn't smashed & rashed:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150618_095502_zpsntqzo5ea.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150618_095502_zpsntqzo5ea.jpg.html)
The headlight / fairing mount bolted up along with the GSXR steering damper:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150618_095522_zpsm6h5qgeu.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150618_095522_zpsm6h5qgeu.jpg.html)
And here's where it sits as of right now:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150618_095435_zpsmupckylj.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150618_095435_zpsmupckylj.jpg.html)
Eye candy. I love it!!!
Slowly coming together! Looks good!
Thanks!
So this morning I powder coated all the wheel spacers and stuff for the rear wheel, and reinstalled all of them:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150619_100911_zpst1yomeds.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150619_100911_zpst1yomeds.jpg.html)
And here's some of the smaller stuff all in one pic... front and rear calipers, misc electrical components, etc.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150619_100650_zpszznasg58.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150619_100650_zpszznasg58.jpg.html)
Very cool! Looking forward to seeing this completed :thumb:
Haven't been on much at all this week Rich so it's great to jump in and see some excellent progress!
Lovin' how she's coming along, can't wait to see some bodywork on!
Fink: me too!
Pete, it's moving along at a pretty good pace now. I'm trying to get as much of the small stuff out of the way now so I can concentrate on the rear end along with properly fitting the dash / headlight surround. Slowly but surely!
Ever wonder what a GR650 looks like when it takes a nap? Put the engine in the frame this morning:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150620_074616_zpsaj4r2n95.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150620_074616_zpsaj4r2n95.jpg.html)
Back on its feet:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150620_075109_zpsvm9lz2tc.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150620_075109_zpsvm9lz2tc.jpg.html)
There are only 2 of the 4 motor mounts holding the engine up right now. I need to powder coat some of the brackets before installing the rest. Maybe tomorrow!
Closer and closer Rich, bet you're getting excited now!
You know it Pete! Unfortunately, the stuff that is left are some fairly large projects.... figure out the wiring, finish the fiberglass seat, weld & fit a new upper fairing mount, make a custom exhaust, etc, etc.
On the bright side, I'll be getting new tires / brake pads front & rear / and a 520 chain soon. All the expensive stuff....
That should take you, what... a week? :icon_lol:
Haha... a week. Maybe if that week didn't include me sleeping or stepping foot out of the garage.
In the meantime though, I finished powder coating the motor mounts and got them installed (the black brackets, not the huge white nut & axle spacer....):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150622_233041_zpssggv5mzd.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150622_233041_zpssggv5mzd.jpg.html)
And so far I've spent about $30 in the past couple days on stainless bolts, nuts, washers, rubber grommets, etc. Since new stainless bolts aren't very exciting to look at, here's a picture of me test fitting some body work while Iget an idea of what needs done:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150621_233005_zpsgj4bo0va.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150621_233005_zpsgj4bo0va.jpg.html)
STAINLESS WOOOO!!! That's the way to go :icon_mrgreen:
I love this bike project... I get probably a bit too excited when I see you've updated/posted :embarassed:
Slowly... slowly the beast comes to life! :cheers: Looks awesome, can't wait to see more!
Great stuff Rich and yeah I'm getting an idea on the finished project now from the mock up, very nice! Can't wait to see her done!!
Thanks folks! Showbiz: I get excited to post updates, so I know how you feel! Menno & Pete: thanks for following along! Hopefully I won't disappoint anybody....
One thing I did last night that I didn't take nearly enough pictures of was the turn signal / license plate mount. Basically a "T" shaped plate I cut / bent / and drilled to fit. Still needs a little bit of work (corners rounded, holes deburred, powder coated, etc) but here it is bolted up:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150625_180701-1_zpslbqkybak.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150625_180701-1_zpslbqkybak.jpg.html)
I bought those led signals years ago and they are the brightest ones I've seen. Unfortunately it appears I've misplaced one of the 4.....
Now, for the taillight area. Everything will be bolted to a this piece of steel that is welded to the frame. Here are the holes laid out and drilled:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150624_233227_zps3adtpkw1.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150624_233227_zps3adtpkw1.jpg.html)
The 1157 bulb mounts bolted on, and led angel eyes mounted temporarily :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150624_234800_zpsuescylhz.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150624_234800_zpsuescylhz.jpg.html)
I have one led 1157 bulb, but the other bulb broke somehow - so I'll be ordering a new one of those.
I had a hard time trying to compare the differences in lighting in pictures.... but here's what I have. Running lights illuminated :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150624_234954_zpsbw0abday.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150624_234954_zpsbw0abday.jpg.html)
And the brake lights lit up (the 1157 bulbs and the led angel eyes):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150624_235021_zpsigz62cfh.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150624_235021_zpsigz62cfh.jpg.html)
My eyes actually hurt from looking at the brake lights trying to take pictures..... last one:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150624_235406_zpsjvk6fuvi.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150624_235406_zpsjvk6fuvi.jpg.html)
Looks like a rocket booster! Haha....
Rocket launch!!!! Haha this is too cool. What is your go-to piece of equipment for cutting metal Rich?
Just a miscellaneous assortment of cut off wheels. I have a couple 4.5" grinders in my garage with different wheels attached, along with a pneumatic tools as well. And of course a dremel for the really small stuff.
Oh, and I've used different jigsaws with metal blades as well. That's what was used to cut & shape the aluminum rear rearset mounts. Little wd40 or similar helps out with aluminim....
That is awesome... I use an air tool with a wheel (no guard, it gets in the way) to do pretty much all my cutting. I force myself to wear glasses/goggles even though it is irritating most of the time lol. I wish I had more of a selection at my disposal, I probably should invest in more of a variety but I've been getting along pretty well so far. THANKS for the tip about the WD40 and aluminum, I will be sure to remember that!!
The machine shop I work at use to be very slack about their safety requirements when it came to grinding metal. Safety glasses were required, but no hearing protection or face shields were necessary. Since OSHA tightened up the rules though, we all got full face shields and hard hats.... the hard hats are kinda silly IMO, but the face shields are awesome! Now I wear a full face shield AND the hard hat when cutting metal in the garage too. When I was only wearing safety glasses, I was still squinting to protect my eyes (and usually goobering up the cut). With a face shield I just go to town with the cutting wheel.
I may have a spare face shield and head harness out in the garage - want it?
Omg that would be sweet... I would totally use it!!! :D And I agree, I squint behind the glasses too.
Deal. I'll check in the morning when I get off work and get back to you.
Very nice Rich! I was a bit worried in the first photo that you wouldn't get enough reflection of the plain steel plate but after seeing the rocket photo I think you're good :thumb:
Thanks Pete! The led 1157 bulbs are dimmer than standard bulbs - I think it's because the leds are only aimed rearward. Should be plenty bright with the angel eyes in there though. If it ends up being a problem, I'm sure I can overcome it..... :)
Little progress today... first the license plate mount without all the parts attached:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150626_100450_zpswjryebsf.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150626_100450_zpswjryebsf.jpg.html)
Now for the problems I ran into.... I wanted to fit up the Hayabusa shifter to make sure I have a proper shift linkage. Come to find out, the Busa shifter has left handed threads while the splined connection on the motor side has right handed threads. Naturally, all my shift linkages are right hand threads on both ends, left handed threads on both ends, or way too short. Not a terrible issue, just needs some cutting / welding.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150626_100507_zpsvtigzjyh.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150626_100507_zpsvtigzjyh.jpg.html)
Since I didn't want to get into all that before heading to bed, I decided to check where the exhaust will end up going. Last time I ran the bike I had a 2-1 exhaust that ran under the engine but it seriously took some ground clearance which always bugged me. I'm going to try to run the original headers, but the stock setup for the shifter pointed up from the shift shafts - and my current setup has it pointing down from the shaft. Again, not a terrible problem since I'll be making a custom exhaust. Still a pain in the butt though.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150626_102646_zps6hdcbzvz.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150626_102646_zps6hdcbzvz.jpg.html)
Oh the joys of custom bikes! Nothing is easy or simple...
I don't know if you remember or not but I initially wanted my pipe to go the right side of the motor, but then when I started the cardboard mock up I realised that would stop me getting the oil dipstick out... :technical:
And of course my most recent escapade with the stacks... replace the carb boots and suddenly the stacks no longer fit :technical:
Going to be so worth it when it's done! Have you considered routing pipes out the other side?
have you thought about duct tape? :technical:
really though, sorry you're having hiccups, hope you get it worked out soon!
I certainly do remember that, Pete. I guess it's all part of the challenge.... like a jigsaw puzzle that wasn't meant to go together.
Menno, duct tape? Don't be silly.... I would have to use aluminum tape at least so it wouldn't burn off! Haha....
Got the shift linkage straightened out today. I overlapped both threaded rods and I tied them together so I could check the shift pedal position, and cut the excess threads off one linkage rod. One 6mm coupler nut and a couple welds later, and we have this:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150628_142522_zpslhfltbzd.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150628_142522_zpslhfltbzd.jpg.html)
Tomorrow: I have to take the swingarm off because I found a part I thought I lost.....
Nicely done Rich!
Oh... a bit off topic but related... I recently discovered SV650/1000 footpegs should fit on a 450 with what should be only a little effort except for the brake lever... it's got my little cogs in my head working overtime on a solution... my shifter mechanism has started to wear again...
I'm all ears Pete.... keep me up to date man! My pegs are in good shape right now, but they aren't guaranteed for life or anything...
Eureka!
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150628_171439_zps2leaux0z.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150628_171439_zps2leaux0z.jpg.html)
I was looking at the bike this afternoon and realized a problem with the prior shifter setup.... with the splined connection on the shift shaft pointing down, it would have been the first thing to catch the pavement if I had an off. It was sticking out considerably more than anything else. If I had flipped the splined connection 180°, the bike would become a "GP shift" which isn't any good either. So after digging around in some boxes of GR parts I found an original shifter that would allow me to have that splined connection pointing up, and now I don't need to mess with the exhaust to get it to clear anything!
Might not be as aesthetically pleasing as a chrome Hayabusa lever, but form follows function...
Nicely done Rich! Keeping those old bits and pieces is always a handy thing to do...
I'm definitely contemplating the SV pegs as an option because I'm starting to miss a change here and there if I don't really hammer her into gear, and the fix for the stock setup is going to be more expensive than a set of SV pegs I think. Getting another 33+ year old 450 setup is only going to have the same wear and tear as I have now.
Three cheers for hoarding motorcycle parts! I'm actually buying another GR650 engine tomorrow as well.... haha.
Got some more stuff done in the garage last night. First, a bracket to hold the front master cylinder reservoir :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150629_224846_zpsv9gamwrr.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150629_224846_zpsv9gamwrr.jpg.html)
Fitted up (loosely) the front fender and the turn signals. The turn signals will probably end up bolted to the fairing, but in this general location:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150630_000418_zpsge4boip0.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150630_000418_zpsge4boip0.jpg.html)
And I discovered another issue last night... the way the taillight shines onto the license plate is pretty much unacceptable. The plate was too horizontal, and only red light was shining on it - which just screams "pull me over and give me a ticket!". So, back to the drawing board for fitting up a fender / rear signals / and license plate. Here's what I'm thinking for a rear fender:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150630_000438_zpsxvl9btj6.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150630_000438_zpsxvl9btj6.jpg.html)
Hmmmm... I say this with some trepidation because I can't see what you're envisaging in your head... but not a fan I'm afraid... I think that style rear guard won't flow with the rest of the bike.
I think ideally you would ignore the need for it and leave that tail piece terminating at the tail light which would be perfect.
Of course in practicality you can't do that... not just for the license plate but if you're like me you still like to have something stopping the crap flinging up from the rear tyre.
Lately I've been thinking if I was to do another project I would contemplate making something up along the lines of what the big BMW's have done... a small guard attached to the swingarm. I've seen someone locally here put one on a customised Guzzi (Breva I think?) and it looked quite good.
I think if you make it subtle enough and have it hug the rear tyre close enough that it can be pretty much ignored by the eye and it won't interfere with the rest of the look of the bike. It both provides a place to mount the license plate as well as keeps all that crap from flinging up from the tyre.
I find it really hard to describe what I'm imagining... :icon_rolleyes:
Nah, I know exactly what you're talking about Pete. This fender is just one that I've had kicking around for a while (remember when it was on my yellow GR with knobby tires?). I do agree that this fender is visually distracting.... but if I were to make a fender mounted to the swingarm, it would end up being "over built" and heavy since I'd be afraid of it breaking off and making a helluva mess....
Oh, and for my plate to be illuminated properly from the current taillight, it would be vertical directly below the lens. Which the rear tire would chew up rather quickly.
Let's see... mounted up the 520 chain (108 links, 16T front sprocket, 39T rear = for my reference). Oh, and I made some aluminum bushings for the bolts that hold the chain guard on:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150630_171721_zpskzgy8v0q.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150630_171721_zpskzgy8v0q.jpg.html)
And trimmed, drilled, and mounted the rear fender:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150630_171804_zpsuvjefqdh.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150630_171804_zpsuvjefqdh.jpg.html)
Since I had the front sprocket cover off to mount the chain, I tossed the carbs on and ran the clutch cable up to the left hand control:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150630_171816_zpsrj4jbusz.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150630_171816_zpsrj4jbusz.jpg.html)
I gotcha Rich... and I get the "over built" part too, if I ever do something similar I will likely have the same result :icon_rolleyes:
I thought that rear guard looked familiar, and now I know why! Such a pity we have to compromise in the name of legality... but we do what we must!
Nice progress as well, she's definitely coming along!
Cheers Pete! I should have added: the current rear fender is by no means permanent. Just a necessary evil towards progress (and getting the bike on the road). It probably will get something shorter / easier on the eyes down the road. I'm planning on adding a removable luggage rack & soft bag support system that would have a more protective fender mounted to it..... but everything is up in the air right now.
Tonight I'll be working on some of the stuff on the rest of the bike.... wiring, some fiberglass, etc... updates to come!
Love the pics and progress as usual, can't wait for more!! I still love the overall shape of that seat :)
Thanks Showbiz! Unfortunately I didn't make any real progress last night. I started laying out the wiring harness and EVERY wire needs shortened or lengthened. When I was out running errands yesterday I bought some ring terminals for the battery & starter relay.... but totally forgot I don't have any heat shrink tubing! Oops...
What else did I do.... I found the 2-1 throttle cable and got it hooked up. Taking the needles out of the slides to hook up the cables (necessary on VM carbs) I realized I didn't drain the carbs properly before letting them sit for a couple years. So those will need cleaned out. Oops again.
Didn't drain the carbs? Ugh... bad Rich! :icon_lol:
A good clean is in order for sure!
I have hit the same place many a time though... progressing well... thinking this is going great! Then realising... ooops.... knew I forgot something! And something else... and something else... :technical:
Having to pull the needles out of the slides to hook the throttle cables up? Really? That sounds painful! Is that the same for all VM carbs or just that particular model?
All VM carbs that I'm aware of. Not really a big deal since the top cap is a large threaded fitting. On your old 450 carbs there were 4 JIS screws, and the 500 carbs have 2 screws before the top cap comes off..... so the VM isn't too bad at all. And if you think about it, hooking up the throttle cable to 450 or 500 carbs isn't a fun task either!
Speaking of GS450's: took the bike out to get some heat shrink tubing at the hardware store 5 minutes away, but it's finally not raining out so it took me an hour. Time to get ready for work rhough...
Edit: all UNIVERSAL VM carbs that I'm aware of. It dawned on me that older GS bikes did come with VM series carbs before switching to the BS series.
Yes true, I hate taking the throttle cable off and it's even worse putting it on!
5 minute ride taking an hour? Sounds about right! :)
Sent from my iPhone using Tapatalk
First things first, I forgot to post this:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/00X0X_jmbAbRn6q9N_600x450-1_zpsof8dd1ax.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/00X0X_jmbAbRn6q9N_600x450-1_zpsof8dd1ax.jpg.html)
Found another engine on Craigslist last week. Missing one header, the starter motor, carbs, and no gasket around the stator cover (hell, it might not even have a stator in it). But for $50 I couldn't pass it up! More good news: iI pulled the carbs off to clean them and I was wrong about leaving gas in them. The left carb was spotless, and the right carb was drained.... but not completely. So there was some varnish in the bottom of the bowl, in the main jet, etc.. I'll take that over an inch of antique gas any day!
Great news on both accounts Rich!
What's the plan for the second motor? Spares or build up a hot rod over time?
Probably just spares. Right now I have a total of 4 GR engines....#1 is in my current frame, #2 has bent valves, #3 is in good shape, and #4 is the one pictured above. The one pictured above gives me some concern though... it was stored in a basement on a shelf, and the motor wasn't sealed up with oil when I bought it. The cylinder walls look pretty good, but there may be rust in the bottom end. So I'll make a gasket for the stator cover and start checking it out then.
Besides, the GR engine is already a hot rod engine to me! :)
Does the fun ever stop? Haha....
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150707_231237_zpsvabvqgcl.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150707_231237_zpsvabvqgcl.jpg.html)
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150708_000825_zpsj3huhhtq.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150708_000825_zpsj3huhhtq.jpg.html)
Lost 5 pounds of copper, gained 10 pounds of solder. ...
I miss projects like these Rich! I am so excited to see that custom fiberglass fender all painted up man. Good job, and keep up the good work!
:icon_eek: :icon_eek: :icon_eek:
You weren't kidding about the harness being a mess!
Good luck, keep at it!
Thanks fellas! Jacob, you know these projects go.... SO much work but worth it in the end. Menno, this is what happens when you keep using and modifying the same harness over and over. On the good side though... I'm about halfway thru the wiring. All the main components are wired, I just need to extend the wires for the rear lights, and shorten all the wires going to the headlights / hand controls.
:cheers: :cheers: Good to hear you're close!
What have you used this harness for, before this project?
I swear next project I do involving electrics I will just make a custom harness... dealing with all the excess wires in a stock harness sends me bat shaZam!... I feel your pain Rich :technical:
Menno, I've been changing this harness since I got this bike... 7 years ago? This is the second time it's been completely chopped up though. Pete, I seriously considered that for this time. But you still have to fit all the connectors (and new connectors aren't cheap!).
Brake pads came in today, so I'm rebuilding calipers.....
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150708_142147_zpsydgsyimw.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150708_142147_zpsydgsyimw.jpg.html)
Very true Rich, connectors aren't cheap at all, although going custom means you can eliminate some of the excess wiring and potentially reduce the number of connectors and the number of pins required for them also, but still... a fair amount of thought and planning is required.
Good news on the brake pads, she'll be a proper roller before you know it!
So.... I've been holding off on the wiring for a couple days for a couple reasons. First, I'm waiting for an ignition switch from eBay and I'm also searching locally for a 5 pin relay. Since the brake pads came in I turned my attention to them. The good news? The front brakes are kinda done..... I was bleeding them and ended up with a good bit of resistance. I did pop all the pistons out, cleaned the seals (wipers), etc, etc. as well. Now the thing that bugs me is that iI'mnot getting a "great" feeling from the front brakes. It almost feels like there is air in the system although no air is coming from the bleeder valve. Maybe my brake fluid is contaminated? Shouldn't be.... but it is possible. So I'll be keeping am eye on that.
Now the bad news. I struggled for HOURS to bleed the rear brake. Tried everything - getting the caliper lower than the master cylinder, using a vacuum to suck air from the bleeder valve, etc... No matter what I did though I couldn't get brake fluid to flow from the reservoir. Low and behold.... the master cylinder isn't building enough pressure! Bastard. Must have a bad seal around the piston or something. Luckily, another Busa cylinder is about $9 on ebay.
Oh, and photobucket is under maintenance, so I'll be posting pics later.
Photobucket is working again - here's the 6 pots ready to go:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150709_235411_zpsjggtfqkc.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150709_235411_zpsjggtfqkc.jpg.html)
Tonight is my "working night" so I should have some more progress tomorrow. ...
Ok. I ordered a Katana / Bandit ignition switch since the stock switch ddidn't stand a chance of working. But because of my fairing mount I had to modify the upper clamp for everything to clear. So much for the powder coating...
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150711_014357_zpswbcntfr7.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150711_014357_zpswbcntfr7.jpg.html)
Ignition switch clears everything now. Still need to notch out the lock material on the frame, but I'll get that later.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150711_014741_zpse2mcozzw.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150711_014741_zpse2mcozzw.jpg.html)
At the beginning of the night, all the wiring for the front end was hanging down like this:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150711_030135_zpsz3qqavma.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150711_030135_zpsz3qqavma.jpg.html)
Shortened and connected the wires for the ignition switch, right hand control, and left hand control (no wire looming until EVERYTHING is wired up and tested - no worries):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150711_030153_zpshomcm90r.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150711_030153_zpshomcm90r.jpg.html)
Last one for the day. Connected wires for the headlight, front signals, and signal relay. Both signals are lit up because I hit the hazard button on the GSXR control.... and they do flash on and off.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150711_045517_zpspai9zwzz.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150711_045517_zpspai9zwzz.jpg.html)
I actually ran out of heat shrink tubing (again) so I couldn't finish up the wiring for the rear end or the digital speedo.
Nice work as always Rich! Glad to see that spaghetti starting to take some form too.
That ignition switch seems very neat in there, like it belongs there. Good stuff!!
Thanks Pete!
I'm waiting for a couple connectors from MikesXS.com (pretty good prices if anybody is looking for electrical connections) so that will take a day or two. But my replacement Hayabusa MC showed up today. Happy to say it only took a few hours of swearing to get that straightened out....still in the process of bleeding the front and rear brakes too.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150715_200248_zps6eaqx57k.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150715_200248_zps6eaqx57k.jpg.html)
Little update this week. I had fork oil leaking on my GS450 so that was a priority.... and then I had a couple days of really nice riding weather..... so not too much accomplished on the GR. Here are the wiring connectors from MikesXS.com :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150716_125845_zpsa8nwgrij.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150716_125845_zpsa8nwgrij.jpg.html)
The 4 pin connector is for the rear lighting so I have a clean & quick disconnect for removing the seat frame. The 9 pin is for an Acewell digital speedo.....which I changed my mind on using. I found a Chinese speedo that has a fuel gauge & gear indicator, so that's in the mail now....
Messing with the wiring some more last night. I was testing the connection on a 5 pin relay and I discovered I needed to change the constant + connection to the relay. It wasn't a switched power source, so my fog light was on all the time if the high beam was off, including when the ignition switch was turned off! But here's a pic of the low beam headlight w/ fog light illuminated :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150719_031851_zpsmwyj3nnm.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150719_031851_zpsmwyj3nnm.jpg.html)
And when I flip the high beam on, the fog lights turns off and the flashlight of God turns on......
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150719_031902_zps0gijx91u.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150719_031902_zps0gijx91u.jpg.html)
Seriously, that thing is blinding. You can see it confused the camera on my phone by the little triangle of greenish lights off the side.
Wow that's some serious light Rich!!!
Thanks Pete! If they were any brighter, they would light up the road for you when I turn them on..... haha.
New back tire came in today:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150720_154032_zpsiydm4kk7.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150720_154032_zpsiydm4kk7.jpg.html)
Pilot Road 3, 150/70ZR-17. Hopefully get it mounted tomorrow.
Flashlight of GOD hahaha I love it!!! Those 3 green dots too wow that made me laugh :icon_mrgreen: WOO for the weather we had for the weekend indeed, finally felt like summer!!!
That is such an awesome looking tire... I wanted that one when I needed a new one for my GS but I went with the Activ instead... I wish I would have gotten that one the more I think about it (so I try not to lol) :icon_razz:
Yes I like the flashlight reference too! :thumb:
A buddy with a gixxer litre bike has his low beam adjusted a few turns too high. .. and a brighter than standard bulb also..
Riding in front of him in the evenings is difficult... often refer to it as Endless Sunrise Behind Me. ..
But flashlight of God is more succinct.. :thumb:
Well, my schedule for work has me flipped upside down at the moment.... usually I'm on steady midnight so my last night off I stay up late working in the garage. Now I have to work daylight shift so my shop time is practically nonexistent. Boo...... but here is the new tire on the wheel, all mounted up to the bike:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150724_011018_zpsoema4wiz.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150724_011018_zpsoema4wiz.jpg.html)
And I ordered some 60mm silicone tubing to be used for an air filter mount / extension:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150728_061924_zpsgcermrca.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150728_061924_zpsgcermrca.jpg.html)
That makes here a real roller now Rich, very nice!!
What's the plan to make use of the silicon?
Holy crap that picture is huge..... sorry. The back bone of the frame is right behind the carbs, so to mount an air filter I need to space it away from the carbs. I used rubber tubing before, but figured silicone was more appropriate.
Later this week I'll definitely be ordering the matching front tire, along with some other small bits. And once my digital speedo comes off the slow boat, I should be able to finally finish the wiring.
Can't wait!! Was showing your thread to my fellow rider and co-worker yesterday... he too is blown away by the awesome work you've done so far :thumb:
You're too kind Showbiz. I'm just slapping parts together the way I think Suzuki should have done in 1983....
Front tire ordered, should be here Friday! Hopefully I can find time to get it mounted.... I was making a "to do" list recently and somehow that list keeps getting longer....
Edit: just checked the tracking # on my speedometer and it's in NY. So that'll be getting here soon too.
Ah got ya Rich, and yes silicone is a better option than rubber I would say :thumb:
Glad all your bits are coming together, can't wait to see her done!!!
You'll end up with the GR Suzuki should've made to go with my scrambler they should've made the year before...
Oh! I forgot to upload this to Photobucket with the others..... but I chopped that plastic fender back a little bit. Any guess on my plan Pete?
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150727_213855_zpsrgltufz4.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150727_213855_zpsrgltufz4.jpg.html)
Hmmm... swingarm mounted one perhaps? :icon_lol:
New front tire mounted (Pilot Road 3, 120/70zr-17):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150801_101026_zpsz7cdadoy.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150801_101026_zpsz7cdadoy.jpg.html)
Mounted a GS500 fender extender to the Bandit front fender - the nuts and bolts are temporary btw:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150801_101132_zpsayrzxfft.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150801_101132_zpsayrzxfft.jpg.html)
And my digital speedo came in from China yesterday. Once I run the wiring, I'll have a fuel gauge and a gear indicator again. Woo hoo!
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150801_101229_zpsnezoazpd.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150801_101229_zpsnezoazpd.jpg.html)
Excellent Rich! I assume there's a bunch of stuff on the gauge once it gets power?
You bet Pete. Right & left signal, high beam, neutral indicator, tach, and speedo. I see there's a low battery indicator on the display but I don't plan on testing that knowing the old Suzuki systems..... I bought a separate voltage indicator for that. And the odd thing? There's no oil pressure warning light. So I'll wire in a separate light for that (which isn't a bad idea IMO anyway).
Good stuff Rich, but yeah I'm surprised at no oil pressure light! That's a very odd thing not to have...
And good call on the voltage indicator for sure! I need to replace mine actually, it carked it a while back...
Pete, you had the multi-colored single led voltage indicator, correct? I'm surprised to hear it buggered up on ya.....
Now before I post this next picture, keep in mind that there's a whole lotta "rough" going on. Rough cuts, rough measurements, rough bare steel, etc.... But I started making a dash panel out of aluminum plate. Drilled the holes for the speedo mounting bolts and cut out a section for the wiring harness to go through, along with a square hole for the voltage indicator. Still waiting for my led bolt to be used as an oil pressure light however....
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150803_003743_zpsga8w8jbz.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150803_003743_zpsga8w8jbz.jpg.html)
I love looking at the rough drafts of things!! Also shows us step by step and how much work really does go into a finished product. Woot for aluminum!! :D
Yup, agreed on that one! That dash will do the trick nicely Rich :thumb: although it lacks the "Buck Rogers" feel of mine :icon_lol:
And yeah I got the one from the UK, 10mm programmed LED. I'm not concerned about it dying as it was marked as not weatherproof but it's still somewhat exposed on the aforementioned Buck Rogers dash. The LED is functional but the PLC chip on the bottom I suspect is what has died. I'll get another and replace it at some point when I'm motivated...
Worked on some more wiring last night. Need to extend the wires for the gear indicator, tach sensor, and fuel gauge though. And the voltage indicator needs to be "hardwired" in, but that will wait until the aluminum plate is finished properly.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150804_022806_zpsvsc34h5p.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150804_022806_zpsvsc34h5p.jpg.html)
Mounted and wired the front mirrors / turn signals too. Here they are turned off (that green-ish light is a reflection from the fog light btw):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150804_022901_zps39o8usb0.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150804_022901_zps39o8usb0.jpg.html)
Signal on:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150804_022904_zpszxqoikj0.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150804_022904_zpszxqoikj0.jpg.html)
Oh yeah - when I took the front wheel off to get the tire mounted I noticed the front wheel bearings were a little.... slow. Not really bad per se, but it almost feels like any grease inside had been washed away with kerosene or something. I figured "when in doubt, swap them out." So I called up my local dealer and they wanted $13.50 for EACH bearing. ... I found them online for $14 for the pair..... which is why my front wheel isn't mounted yet.
Waiting for some other stuff to be rolling in the mail as well. Need to make that license plate bracket still too....
that speedo clock is stunning, please could you post a link, i would very much love to buy it
Here ya go:
http://www.ebay.com/itm/201339327407?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Once I get it wired in completely and test it for a while, I'll post the wiring diagram for it.
Excellent Rich, gauge looks nice and it'll be good with that voltage indicator as well.
Thanks Pete. One thing I did notice with the voltage indicator though: I'm losing approximately 1 volt in the wiring in a short distance. When hooking up a multimeter to the battery it's showing about 13.4v, and the voltage indicator reads about 12.4v (while the battery is constantly hooked up to a tender). Since the indicator is wired into the orange wire coming from the ignition switch, the current isn't passing thru too much wire - mostly just the fuse box and ignition switch.
Just another thing to chase down when I get a chance....
Quote from: Big Rich on August 05, 2015, 04:15:49 PM
Since the indicator is wired into the orange wire coming from the ignition switch
There's ya problem right there Rich!
I run my voltage indicator direct from the battery and have it switched via the same relay as the coils.
Running off the switched ignition circuit will have it running through acres of wiring from the battery through the kill switch and ignition switch, and unless you've dismantled them lately and given them a good clean with contact cleaner you will have some voltage loss as you're seeing.
Before I cleaned my ignition switch and kill switch and before the coil relay mod, I was initially losing almost 2v at the coils, and that's effectively what you're seeing here as the coils in the stock wiring are on the same circuit (I'm assuming the GR is the same in this regard as the 450). After cleaning the switches the best I could get was about a 0.2v drop, but after a couple of years it was up to 0.5v and that's when I did the coil relay mod.
I put my voltage indicator on before I did the coil relay mod, and initially I just had it switched via a horn relay mounted under my dash but I still had the feed coming direct from the battery.
You'reprobably right Pete! I should have mentioned though.... the volt meter is actually fed off of a jumped connection at the speedo (trying to keep all the "dash wiring" on the dash). So it is jumping through a couple different circuits before showing up at the meter. Like I said though, I'll have to chase that missing volt later on.
Good news today: the led bolt for my oil pressure light came in! Now I just need time to work on the bike....
Got ya' Rich, I'd definitely recommend running it direct from your battery if it's possible. It was a bit ugly for me initially having to have the horn relay under the dash but the coil relay mod made it a lot neater to do and let me use the same fuse as well, so much simpler.
Glad you got your bolt in, now I'm keen to see it all together!
That reminds me.... I have a coil relay I need to wire in as well.... more copper vomit.
Anyways, here's the oil pressure light. It doesn't seem all that bright in the picture, but it is like a red laser pointing right at my eye. Which is a good thing for oil pressure.... Notice the fuel gauge is full? I was testing the fuel gauge wiring and flipped the tank upside down on the floor. Upside down shows a full tank, and flipped upright shows an empty tank.... so the gauge works!
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150808_083715_zpsvgwvakin.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150808_083715_zpsvgwvakin.jpg.html)
Excellent Rich! That LED looks plenty bright :thumb:
The oil pressure LED in the Acewell on mine never seems bright enough, but every time it's on (with the engine off only of course!) I never miss it, so I think it'll be fine should such a drastic situation ever occur...
Fitting a coil relay mod? Sounds like an ideal time to run a switched feed from that straight to that voltage panel ;) :laugh:
Ya know Pete, it's funny we keep talking about the coil relay.... I had one wired in the last time the GR was running. But I pulled the wires and threw them in a bin when I was stripping everything down....
I think what I'll do is run a wire from the coil relay up to the digital speedo, and still jump the voltage indicator at the speedometers harness. If I were to run the wire straight to the voltage indicator, the "low battery symbol" would keep flashing on the speedo. Should take care of everything....
Hahaha I think we've all done something like that at some point... nah won't need that again so toss it... oh damn I really need that bit...
That sounds like a good idea to me, I didn't realise there was a low battery light on the dash but yes it would be ideal to keep that and the voltage indicator tied to the same source.
Ok, so I think it is safe to say I have the wiring pretty well figured out. I'll post this here for 2 reasons.... first, in case anybody gets the same speedo and needs a rough translation of the instructions. Second, I'm pretty much guaranteed to lose the paper directions that come with the speedo, and I like to have a reference for myself.
1) Odometer / trip odometer switching: short press of the button
2) Reset trip odometer: under trip mileage, hold button down longer than 3 seconds
3) Kilometer / miles switch: when odometer is displayed, hold button down longer than 3 seconds
4) Other settings: with ignition off, press and hold button. Turn ignition on and wait for the instrument cluster to do its self check. Once settings are entered, turn ignition off to save. First set of digits are tire circumference in millimeters, second set are fuel guage and engine cylinders:
Fuel guage: 1 is for 100R, 5 is for 500
Cylinders: 2 is for 2 cylinders, 4 is for 4 cylinders
Wires:
Green = ground
Blue / white = fuel guage
Purple = tach sensor
Black = positive, switched on with ignition
Red = positive, constant on
Light blue = right turn signal
Orange = left turn signal
Dark Blue = high beam indicator
Brown = positive, auxiliary light indicator
Yellow / white = neutral
Light green / pink = 1st gear
Light green / brown = 2nd gear
Light green / dark green = 3rd gear
Light green / yellow = 4th gear
Light green / black = 5th gear
Light green / blue = 6th gear
Notes: while the red and black wires have different functions, I haven't seen any reason they need to be wired separately. Since there is no clock function (or any other reason for a constant positive while ignition is off), these 2 wires can be wired together.
nice speedo i've seen it somewhere before lol
I refer to it as the "Schultz special". :thumb:
Good idea Rich! 'Tis always good to have another reference somewhere...
Whew! Aside from a missing bolt which I'll be getting probably tomorrow, my dash is done. Smoothed out the edges, used an orbital sander for a better surface finish, powder coated, and used automotive door trim to cover the edges. With that done, I was able to finish hard wiring in the oil pressure light and voltage indicator (but still need to do the ignition coil relay mod and run it up as mentioned earlier). Here's what it looks like now:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150812_201429_zpsflrhzo3f.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150812_201429_zpsflrhzo3f.jpg.html)
Oooooooooh that looks so nice!! Awesome idea with the door trim. What does it look like from behind?
Kind of a wiring mess (imagine that). I still need to run the wires for the gear indicator (6 of them total) along with the speedometer pickup.
Since I'll be rocking the GSXR fairing, I'm not terribly concerned about how the other side of the dash looks. Once I get all the wiring done proper, I'll take a pic of the other side (since right now there's a collage of colored wiring flopping around under there.....)
Mmmm spaghetti... very neat Rich, I like it!
Tie die spaghetti... best kind! :cheers: Looks good so far, Rich!
Thanks folks! It's certainly coming along.... I'm SO sick of looking at wiring though! Luckily, the coil relay is probably the last thing to get wired in (and running a new constant + wire up to the speedo / volt meter). There's still some stuff around the tail section to wire in, but I need to do some metal work back there first.
Tomorrow I hope to get the fairing "finish mounted" to get a better idea of what the front end looks like. One day at a time....
I hear ya' Rich... wiring is great when you get it right and neat, but drives you insane on the way!
Woot! Big day today..... for a couple reasons. But first, a pic of the front end wiring without the fairing (I still need to make a mount for the speedo sensor , that's why it isn't hooked up):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150814_163606_zpsffddsnyf.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150814_163606_zpsffddsnyf.jpg.html)
I did the ignition coil relay mod and ran the wiring up to the speedo / volt meter. I was losing about 1.5 volts through the stock wiring, and am now only losing about .7 volts in between the voltmeter and a direct reading off the battery. Fairing somewhat installed:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150814_180234_zpsnhtc9lzq.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150814_180234_zpsnhtc9lzq.jpg.html)
Now, I know the headlights look low in this picture..... because they are. I drilled upper holes and lower holes in the mounts when I was fitting everything, and I ALWAYS put the lights in the lower holes by accident. So those will need moved to the upper holes.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150814_180345_zpsmbtsfi22.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150814_180345_zpsmbtsfi22.jpg.html)
Cleaned the windscreen, and don't have the tank installed for the pic. But just an idea of the end product:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150814_213114_zpss8zcqw2g.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150814_213114_zpss8zcqw2g.jpg.html)
Now that the pictures are out of the way, the other good news: I got to fire up the engine today!! It made an unholy racket since I only had headers bolted on (made some nice fireballs too.... haha). One of the last wires I need to hook up is the tach sensor, which is why I fired the engine up. Good news: it purrs like the day i parked it a couple years ago. The bad news: the tach isn't accurate yet at ALL. In all fairness though, I could only test with what little bit of gas was in the carbs at the time. And the exhaust was so obnoxious that I didn't want to keep revving the engine.
Hooked up the gear indicator, and it works just fine too. That's it for now!
Great work Big Rich, love it.
Can't wait to see it finished.
Great stuff Rich, that's awesome!
Are you using really thin wire for the run to the dash or something? Losing 0.7v sounds way wrong... I haven't been able to measure a drop at all in that run... but you know I just have to have it right don't you? Haha
Are you planning to put some automotive trim around the healight holes to neaten them up a bit or something along those lines?
Great to hear the engine is still purring along and man I'm itching to see her start going together again!!
Well, that measurement was.... sporadic to say the best. I saw what the volt meter read and thought "Great!". Then started doing something else for a while, them remembered to check the voltage at the battery. I can say that while the engine was running the volt meter was reading around 13.2 volts. Can't be that far off, right?
And there are some plans for the headlight surround, no worries. It involves fiberglass, plexiglass, etc....
If it's reading 13.2v at idle that's pretty good! :thumb:
And I'm keen to see what you do for the surround in that case... sounds interesting!!
The headlight area is towards the bottom of my "to do" list for a little while unfortunately. Right now I'm trying to get the bike in a slightly rideable condition so I can start working on any bugs that come up. Speaking of which, I did work on a turn signal / license plate mount last night:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150816_023836_zpsjh85pkpp.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150816_023836_zpsjh85pkpp.jpg.html)
Those plate lights were needed since the tail lights didn't illuminate much.... still have a bunch of work ro do on the mount and wiring, but that's the direction I'm headed.
I rolled the bike outside for a good picture, and you can see how the rear signals / license plate will sit when finished:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150816_160645_zps59imzerk.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150816_160645_zps59imzerk.jpg.html)
That's it for now.... ordering exhaust components tomorrow though.
I like it Rich, looking good already!! I like the stance and the lines should flow nicely once that seat pan is finished up.
Do you have regulations regarding the plate mounting? Over here I'd be pulled over and fined in about 30 seconds flat I reckon... it needs to be readable from 20 metres away I think so that would be on too much of an angle to be legal here.
Cheers Pete! Right now the angle is at its extreme, so it will be tweaked before it is all finished. But here is what Pennsylvania's inspection code says about the license plate:
Inspection will be rejected if:
(B) The license plate is hanging loosely from its mounting bracket.
(C) The license plate is obscured so that the numbers cannot be identified.
(D) The license plate lamp, if so equipped, does not illuminate the license plate.
Pretty slack, huh?
Quote from: Big Rich on August 17, 2015, 01:47:19 PM
Cheers Pete! Right now the angle is at its extreme, so it will be tweaked before it is all finished. But here is what Pennsylvania's inspection code says about the license plate:
Inspection will be rejected if:
(B) The license plate is hanging loosely from its mounting bracket.
(C) The license plate is obscured so that the numbers cannot be identified.
(D) The license plate lamp, if so equipped, does not illuminate the license plate.
Pretty slack, huh?
you want slack? Illinois requires no inspection.... buy it, chop it, ride it....
Just needs a headlight, brake light, speedometer, and 1 mirror...
No turn signals required either..
Wow you guys get it so easy!! We have minimum front/rear mudguard lengths, license plate visibility, indicators must be a minimum distance apart, handlebars must be not too high (no big ape hangers here!), and the list goes on and on and on... and while a lot are good things from a safety perspective, some are just ridiculously pathetic and make customs difficult...
Yeah, we can't really complain. And a lot of the small stuff can kind of be ignored as long as you're not being a jerk. PA requires an annual inspection of vehicles, and motorcycles can pass really easily. When I did my 450 last, the mechanic walked outside, looked at my brake pads and tire tread depth (literally looked, not measured.....) and gave me a sticker. He even said "you rode it here, so it can't be that dangerous".
The days of that here are pretty much all gone... the guy I got to do the safety certificate on mine was great, but his hands are tied on some stupid things.
Woot! Most of the exhaust tubing came in!
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150825_204231_zpssjsjihfn.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150825_204231_zpssjsjihfn.jpg.html)
I want to get the "mid exhaust" fitted up before the rear of the exhaust due to the angles & length.
Nice Rich! I really wish I could weld well enough to make my own exhaust but I can't see that happening any time soon! There's still Tranzac here who did mine though so I can't complain :thumb:
Wish I could weld as well as the lads at Tranzac! Seriously Pete, you have the best 450 exhaust I've seen. I actually want to work on my 450 exhaust a little, but it needs to wait for obvious reasons....
But I did start cutting and welding the tubes tonight.... gonna push to get the mid section done sooner rather than later....
Well... he did do a damn good job on mine! Still love lookin' at that pipe... and listening to it... haha
Keen to see how yours turns out!
Ok, the mid section of the exhaust is done. I took the pipes shown above and made this:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150828_230815_zps8tfzlgzi.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150828_230815_zps8tfzlgzi.jpg.html)
For anybody interested in cutting their own pipes (exhaust, roll cage, etc), this tubing calculator is freaking awesome: http://metalgeek.com/static/cope.pcgi
Left side of the exhaust has the 90° bend, clearing the kick stand and the shifter:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150828_234958_zps6atb1njq.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150828_234958_zps6atb1njq.jpg.html)
Right side of the exhaust:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150828_235031_zpsrvvtugfq.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150828_235031_zpsrvvtugfq.jpg.html)
I need to order 2 more sections of tubing to get the muffle where I want it, so it will be over a week before those come in. While I'm waiting, I will end up powder coating the pipes I have though.....
Nicely done Rich! And that calculator looks extremely handy!
Thanks Pete!
Got the exhaust powder coated black and mounted back up:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150901_013714_zpslpta4o4w.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150901_013714_zpslpta4o4w.jpg.html)
Also painted the exhaust clamps black so they don't stick out like a sore thumb....
Looks the goods Rich! Did you say you were doing something different with the muffler end as well?
Yep. I wanted to put together the mid section so I can see what pipes I need to finish up the tail end. Ended up ordering a 45° up swept pipe, along with an 18° pipe. So the muffler will sit at a a 27° angle.
If it all works out as planned, I should be able to give it a test ride in about 8 days.....raw fiberglass seat and all.
Great work as always Rich!!! And as always, thank you for sharing :D
That's great Rich! Need to see that on video!!! :icon_mrgreen:
damn i miss my tempter lol.
Aaron, I have 3 spare engines and a titled frame. And a ton of spare parts....
Years ago while browsing around on Craigslist for spare GR stuff I found something pretty interesting. Somebody took a GR650 engine and fitted it to an adult sized go kart frame with those "all terrain" golf cart tires. The ad said something along the lines of "You have no idea how fast this kart can go!!!"
Yes...yes I do.
Small picture-less update: the last 2 pipes I needed for the exhaust came in today. Really wasn't expecting them until tuesday.... but I'm not complaining! Hopefully I can get the time this weekend to finish off the exhaust.
And I think I need to get a new battery.... my current Shorai isn't holding a charge well at all. If the bike doesn't fire up right away, the battery drops down under 11 volts.... bastard. Not exactly what I want to spend $150 on right now.
Gettin there....:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150905_100447_zps4ap0vw1e.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150905_100447_zps4ap0vw1e.jpg.html)
Obviously that's just a test fitment. The muffler will be slid down the pipe a little ways so it's not sticking out the rear of the bike.....
Have a safe & fun holiday weekend folks!
That angle looks spot on Rich! I can imagine it slid further down and it should be good!
PS... just gotta say I just purchased the real start of my next project... an import 750 Kat frame ;)
What?! The Kat project begins?! That's awesome Pete. Are you going to have a thread on the GSR, DTT, etc?
But yeah, the exhaust is turning out pretty well. I have some soft bags that have a very similar angle, so it should be pretty slick when it's all said and done.
It does indeed Rich! Still a long way to go... that's a sum total of 2 parts towards it... haha
Dunno about DTT (haven't logged in there for a very long time) but GSR and the Kat forums for sure :thumb:
I remember seeing the soft bags somewhere so yes that should all work out very well indeed.
Well Pete, I'm excited for ya. I know you've wanted a Kat for a long time now. You do some great work, can't wait to see it!
In regards to the shorter muffler, this looks much better:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150906_204912_zpsurbmpz5h.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150906_204912_zpsurbmpz5h.jpg.html)
Shortened the pipe and slid the muffler down, and welded some exhaust supports on. Still needs some finish welding / grinding done..... but I got to take it for a little ride today! Just a few 1.5 mile loops around the neighborhoodto check the speedo settings, but it felt good to twist the throttle on this again. My butt however, reminded me how iI need some padding on the seat.....
all part of the process lol, all part of the process :)
Congrats on the promotion Yama! But yeah, I left out the part about the fender falling off and me driving around for 20 minutes trying to find it.....
updates tomorrow, I swear!
I'm excited too Rich! Will let you know when I have threads up.
That's awesome you got to take her for a short run! The pipe is spot on now, looks good and suits the lines just right.
Sent from my iPhone using Tapatalk
"Tomorrow" took longer than I thought......
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150911_092106_zpsswek789r.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150911_092106_zpsswek789r.jpg.html)
So let's see.... finished powder coating the exhaust, and added a little bit of exhaust wrap (only near the brake lever to prevent boot burning). Took the seat frame completely off, sandblasted, and painted it for now. It will get a proper powder coated finish once everything is done, but for now I just need to prevent rust. And I made a gasket for the taillight lens so water can't get in there. If you look real close around the carbs, there's a black hose connected to the cylinder head. That's a GR650 thing.... originally there is a hose between the cylinder head and carbs that sucks a small amount of filtered air into the intake. Because the air comes in at an angle, it "swirls" the intake mixture for some type of performance gain. Since I don't have stock carbs, I would use rubber vacuum plugs to block the holes. They always get too hot and leak, so I finally got a silicone hose on ebay to do away with those rotting plugs.
OH very nice Rich, very nice indeed!!! The pipe looks good and the seat is taking shape nicely too! I'm gettin' excited!!!
So I've put about 30 miles on the bike so far and here is what I've found out:
My suspension is pretty much crap at the moment. The Ducati rear shock w/ stock Suzuki spring might work for the GS750ES, but the GR650 is just too light. Same can be said about the Bandit forks - I was hoping the springs would work but they are too stiff. Right now the plan is getting hold of Rich Desmond about some "ultralight" springs (his Bandit springs go down to .85, and I need .75). I'll also be looking at a Hagon rear shock to replace the stock GR650 shock, but that's another $450 or so.
Brakes? Oh yeah, there's some issues there too. One or both of the front rotors are warped badly (haven't measured which yet obviously). I really don't want to go with Chinese rotors, so I need to browse around on ebay for hopefully slightly used replacements. The rear rotor is good, but the pads aren't gripping hardly at all. Maybe they are glazed over? Have to look into that as well....
Between the stiff suspension, non padded seat, and low / long riding position, the bike is more of a torture device at the moment. A loaded tank bag really does help to take some pressure off my wrists, but I need to get some tank grip pads before it's all done. My death grip on the tank digs my knees into the steel...
All that being said.... it's a blast to ride and I can't wait to ride it again!
Niggly bits aside that sounds like success to me Rich!!! Hopefully you can get those sorted fairly simply/cheaply and get on the road sooner rather than later :thumb:
Cheers Pete! I'm really going to try and avoid the Chinese rotors.... I've found a few OEM ones on ebay (used of course) but need to wait for payday. Besides, I still need to measure and find out if just one is warped or both.
Update! Took the screen off and painted the lower edge of the inside of it. This will help to hide some of the dash wiring, and it doesn't block my line of sight at all either:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150917_023029_zpscv0mk3uf.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150917_023029_zpscv0mk3uf.jpg.html)
Took these sections of the exhaust off and sprayed the wrap with some black header paint :
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150917_023017_zpsha19fzf1.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150917_023017_zpsha19fzf1.jpg.html)
Last for tonight - started making a seat pan using fiberglass and wood paint stirring sticks. The wood is for stapling the vinyl later on:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150917_023006_zpssvvgdfgl.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150917_023006_zpssvvgdfgl.jpg.html)
Excellent Rich, it is coming together nicely... The finish line is in sight!!!
Sent from my iPhone using Tapatalk
It's looking good Rich, keep up the good work :thumb:
Well, I've been working a ton of OT at work, and have only had brief chances to get in the garage. But I found this little gem on ebay recently:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150928_181302_zpsrdqgmznb.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150928_181302_zpsrdqgmznb.jpg.html)
Some NOS case savers! As much as don't generally like the look of case savers, they do have some appeal considering the alternatives....
And I started putting some padding on the seat. There's more than what this picture shows, but I was in a rush working in the garage. The soft saddlebags are weighted down to help the adhesive stick to the fiberglass pan:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150925_085538_zpscv4ns15v.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150925_085538_zpscv4ns15v.jpg.html)
Once the padding was down and shaped, I started fitting a cover over everything. There's only 6 staples or so in it right now, hence the loose fitment. Tomorrow morning I'll finish up my 12 night stretch at work and can get some more garage time.....
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20150928_182022_zps3lqdvwog.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20150928_182022_zps3lqdvwog.jpg.html)
Excellent Rich! And great score on the case savers! Would love a set on the 450 if I could get them to work around the pipes...
Are you going to be ok doing the fibreglass finishing and paint with the seat on there already?
Sent from my iPhone using Tapatalk
Cheers Pete! Have you looked into case savers for the GS500 or maybe some frame sliders? Surely something would work with your pipes....
But yeah, the seat shouldn't be a problem. The foam & vinyl rest on top of a separate fiberglass pan that will only be attached with velcro. I want to do the seat pad before the fiberglass tail, only because the way the fabric sits will effect how I do a "finish trim" on the leading edge (by the gas tank).
I thought about making some up at one point but the prices of the raw materials were a bit :o :icon_eek:
Still something sitting in the back of my mind though for sure... it would still be cheaper than the end result of going over...
I had forgotten you had a separate seat pan despite the fact it was only a few posts up in the thread :technical:
You'll be just fine in that case :D :thumb:
Good idea to do it this way, it will definitely fit in better with the tank!
Just took the old GR for a 70 mile run.... and WOW this bike wants to go fast! It is pretty brisk outside right now (a whopping 45°) but the fairing definitely kept a good bit of wind off me. Years ago when the bike was stock, I really had to push to get it to 100mph, today I hit that with some revs to go. Now for some things to add to my "to do" list:
The fairing mounted mirrors are pretty worthless. Looks like bar ends will be the way to go.
Which means new front signals will be needed as well.
Electrical: with the 1157 led taillights, my system is almost "over charging" at high rpms. With standard bulbs, it is dropping down to 13.1-13.4 volts at idle. Gotta pick the rock or the hard spot I suppose....
The kick stand needs a peg welded back onto it - it is tucked away behind the shifter and exhaust, and I'm no contortionist....
Throttle grip is sliding off the tube, so that needs attention.
The seat is rock hard! Probably just get an Airhawk pad and see how that works out.
Aside from the seat being rough, the suspension needs some work too. The Bandit springs are way too stiff, so I need to email Rich Desmond about some ultra light springs. The whole front end may have been beefed up when it was actually on the Bandit, so some 10w oil is going in too.
That's awesome to hear Rich! All those things should be relatively easy to sort out, the fact that she's running well is great news!
It's definitely good to have usable mirrors... even on mine I find the stems are probably an inch too short and I get a little too much shoulder than I like, but I can see enough behind me it's not a major drama. I'm not too sure about 'bar ends for filtering though... extra width is something I don't need for that! Haha
I hear ya Pete - it seems like cycle mirrors are always a compromise. I think the only standard mirrors that allow a good FOV have stalks that are so long to allow vibration. I put some small CRG bar ends on the GR and they seem to work out so far..... but being on clip on bars, I might get a great view of my future saddlebags instead of traffic. Time will tell.
Some good news though - I emailed Rich Desmond about some lighter springs, and he said he actually has some in stock - they just weren't listed as in stock on the site.
One other thing.... I don't know if I mentioned it but my front rotors are pulsating pretty bad. I tried soaking the buttons / rivets / whatever they are called with brake cleaner and unsticking them. That helped a little but I think I'll need to find the exact high & low spots on the rotors. Always something....
Yep, mirrors are hard to get right! I've seen a few guys (mainly Harleys) with mirrors that run from the 'bars but hang underneath, so you're looking out under your arms... may or may not work, I'd have to see for myself.
Good news on the springs and yes I remember the pulsing discs, definitely need to get that sorted! Don't wanna have to grab a handful of brake just to find the pistons have been pushed back in and you have to pump them up again first :o
Not much to update since I'm working a bunch of overtime again. I got the seat fabric to look somewhat presentable, s iI've been riding the GR more often. The bushing in the clutch handle on my GS450 is causing some notchiness, so all the more reason to park the GS and ride the GR anyways.
And a neat pic I took the other day:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151007_225316_zpsoyy5briq.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151007_225316_zpsoyy5briq.jpg.html)
Haha nice!!! I love it... and that seat is really coming along nice!!
That's a nice angle Rich, she's looking great already!!!
Thanks fellas!
My time has been rather tied up lately.... between working overtime, tinkering with that little blue electric bike, and the yellow dirt bike, I haven't gotten too much done on the old GR. Last night was my "garage night" and I only took one picture...... boo......
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151011_181546_zpsrm6qehrr.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151011_181546_zpsrm6qehrr.jpg.html)
I did open up the headlight hole on the fairing, along with the first couple coats of metallic primer. Needs a light wet sanding and a couple more coats though before I can lay out the rest of the paint scheme. I had to swap out my ADVMonster fog light (that was in front of the engine) with another one. Let's just say it didn't agree with me messing with the lens..... But I swapped the ADVMonster lights from the GS450 & GR650 too. The light on the GS is a different model, and MUCH brighter than what was mounted on the GR.
That's it for now!
Well one pic is better than none :icon_mrgreen:
Can't wait to see the paint!
Is the seat pan steel ???
I am thinking I'll pull that out of storage and take off the foam and cover (too bad, that thing is mint) sit it on the bike and bash it flat in the center, hack off the tongue in front and hack off the rear 1/2.
Cool.
Buddha.
The stock pan? No, it's molded plastic. And it has a ridiculous step up for the passenger seat too.
Quote from: Big Rich on October 23, 2015, 03:03:39 PM
The stock pan? No, it's molded plastic. And it has a ridiculous step up for the passenger seat too.
Oh even better. Bashing it wont be an option, but cutting it is easier. I may do a 2 piece one though. Or get a rear pan from something like a shadow and mod it.
Problem is, without the seat, I cant do the rear hoop and fender.
Yea the seat step is retarded, but the frame is the real culprit, and WTF does it need that 6" step and a seat latch on top of that.
Cool.
Buddha.
Love looking through people's builds, looks like you're doing some fantastic work!
BigRich: This is the look I am after -
http://gr650.bplaced.net/bilder/cafe6.jpg
http://gr650.bplaced.net/bilder/cafe1.jpg
Is it possible I have hacked off too much. I cut its rear fender carrier off and cut the lock brace off.
The thing is, that rear fender is still fugly, so I will adapt something to it.
Cool.
Buddha.
With some extra foam under the riders seat, and minimal foam under the passenger seat, it should be possible to get a flat seat overall. I would have to look at a stock pan, but there might be a problem..... the passenger area of the pan has a wide / flat spot in the plastic.
I enjoyed working with different fenders for the GR. From a Harley fender, to a universal plastic fender, they all looked better than stock (IMO)
Putting extra foam on that seat would turn it into a barcalounger. It used 3000 tonnes didn't it. 80% of the cost of that bike was the foam in the seat LOL.
That rear fender is fulgeeeeeee ... Yea I think I did the right thing. That seat in the pic may have been shaved to that hump for the brace - sorta like they shave it to be flat to the level of the hump.
Cool.
Buddha.
http://gr650.bplaced.net/bilder/cafe2.jpg
You can see the step in that pic - its sorta spreading the vinyl a bit
But its a masterful job.
Also your idea seems to have been implemented by this guy.
http://gr650.bplaced.net/bilder/gr05.jpg
Looks 1/2 decent in-spite of having more foam.
Cool.
Buddha.
Haha, Buddha you should have seen my seat when iI first got the bike. The PO added so much foam I couldn't even get my toes down. There's ways around everything with a little effort.....
Ya know, that first bike kinda scares me a little. Why add dual shocks to a frame that wasn't engineered for them? And the external springs on the forks?
This bike is crying out for dual shocks, and the shock linkage for it is a freaking work of art, if you're a sadist.
Springs in front could be just for looks. See how dinky they are. Sorta to "age" it. As is that paint job.
That is the tempter's tank right ? not a swap ?
He's done a lot of work I'd simply not do, the gauge cluster, polishing all the aluminum etc etc. But the rear shocks isn't one of those. I've toyed with that myself. I may just go with 86-87 GSXR 1100 - dual eyelet shock pr something similar.
That bike almost makes me want to ge ta complete running tempter and most the seat to show me how stupid I was. Modding the rear fender to not look hideous is far easier than hacking the tail off like I did.
Cool.
Buddha.
http://gr650.bplaced.net/bilder/cafe2.jpg
What is that under the seat - a chrome rod side to side ?
Maybe he's hacked off stuff and put that "bench" seat on it.
Cool.
Buddha.
Looks like a passenger grab rail to me?
Quote from: Big Rich on October 24, 2015, 12:49:36 PM
Looks like a passenger grab rail to me?
Which begs the question - what else was hacked/welded. The side cheeks to carry the grab rail are hideous and huge. They have disappeared in that bike. I think stuff has been cut and covered up with that seat fabbed up flat.
Cool.
Buddha.
Quote from: The Buddha on October 24, 2015, 11:39:05 AM
http://gr650.bplaced.net/bilder/cafe2.jpg
Been poking around with that frame and seat (which I managed to locate in my stowage) and side covers - which BTW if you have a set, I'd like to buy it off you. Mine are red with rattle can black over it, and the bike is blue and silver. Anyway,
That part where the upper shock mounts are in this bike, there is a huge freaking gap between the side cover and frame.
I have to either weld a lip to the frame or rivet a strip of plastic to the side cover, else it would look retarded. Or fit a shock mount ... LOL.
That seat pan needs to be hacked up right as it starts the rise - front and back of the riders butt. Some high density foam oughta do the trick of being as comfortable as a bench.
Cool.
Buddha.
You're in luck Buddha - Iactually do have some plastic side covers . I'll have to get some pics for you.
Quote from: Big Rich on October 25, 2015, 02:26:09 PM
You're in luck Buddha - Iactually do have some plastic side covers . I'll have to get some pics for you.
You dont have to do that, what color is it, and does it have any cracks ?
That's about it. I hope to not paint it, so silver/blue would be perfect. Else, I'll paint it I guess.
Cool.
Buddha.
They are the maroon / black ones. There is a crack on one side.... I can't recall which side, but it is a non conspicuous spot. Tough to describe, but it is under that black wing section next to the airbox.... definitely need to take a picture.
OK cool.
Thanks.
Buddha.
Update: I bought a part for my Supertrapp muffler. I had a 120° shroud on the end, but wanted a 360° shroud to deflect sound away from me:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151025_150855_zpszmcx1qfc.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151025_150855_zpszmcx1qfc.jpg.html)
Did you guys know there's a decibel meter app for Android phones? I didnt, but do now. With no end cap on the muffler at all I measured the sound with the engine humming around 2k rpm. A whopping 90db in my garage! Ouch.... with the 360° shroud and spinning 2k rpm, it was only 82db from the riders seat.
Nice work Rich! That's a handy app indeed... will have to look if they have one for iPhone as that would be very handy indeed...
I really like how you fixed the rear frame of the GR. Simple solution yet effective at fixing the body lines.
For the cafe look, the GR has a gra motor and decent tank but the rar section is horrible.
Baron - thanks for the props man! It's been a long journey, and it's not over yet. Thanks for tagging along!
Pete - I'm sure they have something for IPhone. I mean, they HAVE to, right? Haha..... while I can't whip out my phone to get out of a "fix it" ticket, it is good to know how much racket the old 650 is making.
JFman! - we keep running into each other in joints like this.... good to see you here too bud. Hope all is well on your side of the border!
Yep found one Rich :thumb:
I'll have to give the 450 a shot at some point just for curiousity's sake...
Quote from: Big Rich on October 26, 2015, 06:20:39 AM
They are the maroon / black ones. There is a crack on one side.... I can't recall which side, but it is a non conspicuous spot. Tough to describe, but it is under that black wing section next to the airbox.... definitely need to take a picture.
That rear inner plastic fender would be good too.
Cool.
Buddha.
This looks like terrific work so far! :o
Well done indeed! :cool:
Thanks Moto! Buddha, I didn't forget about you either. Life stuff - ya know.....
Some pretty big updates coming soon. Made an engine stand out of some scrap parts, so it's time to do work son:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151111_115436_zpsjj6izv5z.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151111_115436_zpsjj6izv5z.jpg.html)
Good deal Rich, can't wait for some serious updates!!
I made an engine stand for the Kat motor but I used some scrap timber and bolted it up to the work bench so I's a very handy height to work at too :thumb:
Metal would be better but... well... I'm sure you've seen my welding ;)
Cheers Pete! Hopefully you're smarter than me and drained the oil from the engine before bolting it to the stand.....
Two of my recent big $$ purchases - good old Sonic Springs for the Bandit forks, and a pair of front rotors:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151114_215413_zpstnpsyh9o.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151114_215413_zpstnpsyh9o.jpg.html)
Here's my plan so far with the engine: the bottom end in the stand will be used, but many parts will be swapped onto it. Side covers, cylinders, head, etc. All my gaskets should be here on Wednesday or so..... Stripped down a little and the base gasket removed:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151114_215441_zpsndtgfnbc.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151114_215441_zpsndtgfnbc.jpg.html)
Ever notice the Suzuki logo behind the starter motor cover? No? Well, I shaved that off:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151114_215525_zpskeh5sy1q.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151114_215525_zpskeh5sy1q.jpg.html)
We are supposed to get some really decent riding weather this week (above 60° in November?!) , so the bike is getting stripped down for winter work in about 5 days.....
No worries about my parts.
The GR motors I have are rolling around on casters welded to its frame rails that I cut off. I guess I never intended to ressurrect those 2.
I should have kept the 2 GR's I picked up @ junk yard, but I bought em just for 1 piston. Then I found that piston in my hood from another tinkerer who made a 851cc GR motor equipped GS.
Cool.
Buddha.
New rotors installed:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151115_222141_zpsdoegxztr.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151115_222141_zpsdoegxztr.jpg.html)
Unfortunately, my speedo magnets don't fit these rotors. So I'll need to find some new magnets / figure out a solution over winter. Also got all the gaskets cut off from the bottom end I plan on using:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151117_142314_zps4b7ys0wd.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151117_142314_zps4b7ys0wd.jpg.html)
Good work Rich, and it's always good to get new bits!!!
As for the oil, yes someone already did that for me thankfully :D
Got 3 great days of riding in this week.... but last night ended up like this:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151120_023951_zps1x4qfbsm.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151120_023951_zps1x4qfbsm.jpg.html)
Riding season is over, wrenching season has officially begun! I didn't take a pic of the other motor, but the pistons & jugs got swapped over. Once I replace the valve seals, the top end can go back on. The clutch cover and stator cover got swapped too..... I have to say pulling the engine from the frame is SO much easier without the top end installed.....
I'm sitting back with the popcorn Rich :D :thumb:
Cheers Pete!
I figure right now I have 4 GR650 motors: the one I'm building up now will be the runner. The engine that was in my yellow tank / dirty GR (remember that one?) is also in good shape as it sits. Then I'll have 2 engines laying around for spare parts since they aren't complete enough to try and rebuild..... so they will get all the necessary gaskets to hold oil while they sit in storage.
Took my chrome crash bars into work this week to get them shot blasted (prep for powder coating), but the machine is down so far. Just need them done before winter, that's all.... And if i find the time in between shifts I'll get my valve seals swapped out for some fresh ones.
Sorry for the lack of updates - I've been working on the engine so much and my hands have been covered in oil.....so no progress pics. I did get quite a bit done engine wise though: new gaskets all around, cylinders got a quick hone, new valve seals, lapped the valves slightly, valve shims in spec, and everything got reassembled properly.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20151128_035343_zpsxlmazd93.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20151128_035343_zpsxlmazd93.jpg.html)
I had the chrome engine guards shot blasted and they got a fresh coat of black powder, and the kickstand got some work too - years ago I cut the little peg off since it was in the way. Now, I had a hard time reaching it.... so a peg got welded on and the kickstand got some powder too. I recently had a small "issue" with the engine, but I'll get into that a little later.
Nice work as always Rich, it's great when that engine gets assembled and everything is in spec, such a good feeling that!!!
Cheers Pete!
After getting the engine together, I did what any normal person does = try and fire it up! Little bit of gas in the syringe to feed the carbs, turn the chokes on, and it started up no problem. After letting it warm up for a minute or two, I shut the choke off on the right carb (no problem yet), the shut the choke on the left side off.... and the idle dropped considerably. Some messing around and experimenting led me to this - the left cylinder is only running with the choke on. I'm thinking there is a major air leak on the left carb intake, and the choke (fuel enrichment) is providing enough gas for it to fire. I'll be messing with it over the next couple days, so I'm not worried about it.
Hopefully that's all it is Rich! Should be a nice simple fix if that's the case :thumb:
i just want to say 'engine stand win,'..... :thumb:
Ha! Thanks Cbr. I was wondering how long into winter before somebody went and bumped the project threads (I had considered doing it myself.....).
Not a whole lot to update on mine - working on the beginning stages of paint for the fender & fairing, smoothing out the glass on the seat, and creating some "storage space". Hoping to get some steady garage time after Christmas.
Ok, so I guess it's time for some actual progress. I did the primer and color coats on the fender and fairing..... but not the clear coat and pinstripes yet:
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20160105_214901_zpshxxsrjli.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20160105_214901_zpshxxsrjli.jpg.html)
Still chugging away at the fiberglass seat (kicking my butt btw!!) and working on some saddlebag mounts around the seat frame. I'll be ordering (and learning how to use) pinstriping stuff soon too. But the fiberglass seat is on the top of my priority list after the clear coating of the fairing / fender is done.
Glad to see the progress Rich, looking good as always!
What's kicking you with the seat? General shaping or just getting a smooth even finish on it? I do recall getting that smooth even finish was the most painful part of all.
Thanks Pete!
Yep, trying to get that smooth / even finish. Adding fiberglass, letting it cure, sanding smooth, etc.... it's taking a lot longer than I had thought. I'll get it, just wish I had an "easy" button. Ha!
That looks awesome Rich... a really cool pic to start my morning with :D
I hear ya about smoothing out fiberglass... I'm to that point on a lot of areas on the Spirit... ditto on the easy button!!!
Yep that's the tedious bit Rich! But it's worth the effort and patience, you will be so glad you took your time with it when you're done.
ShowBiz... what's the Spirit? Sorry Rich gotta hijack for curiousity's sake :D
No worries on my end Pete. I don't mind talking about the most awesome mid 90's econobox:
http://gstwins.com/gsboard/index.php?topic=69125.0
Showbiz does some amazing artwork..... which is why I consulted her for the paint on my GR650.
Ok cool, now I I'm with it, talent there for sure! :thumb:
Just saw this now... sorry for missing your question Pete! Yeah I stopped updating that thread but I have been working almost every weekend on the car. Maybe I'll update the thread with some pictures this weekend... thank you for the complement!!
And Rich, thank you for your kind words about the Spirit... Ya made me blush :embarassed: :D
No probs ShowBiz! I have the artistic ability of a snail so I appreciate the talent of those that have it :D
I did however successfully draw a stick man once :thumb:
Neeeeeeeed update plz :D
Haha..... I was wondering how long I could slip under the radar..... I have made a good bit of progress, but mostly rushing things a little since riding season is approaching (or at least a couple nice days between snow falls). And I really haven't been taking any pictures as I go. First, I cut and buffed the gas tank (sorry about the dark pic..... cell phone camera in a dark garage = low quality):
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20160124_082016_zpspj1qzj5h.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20160124_082016_zpspj1qzj5h.jpg.html)
And believe it or not, this is the only other pic I have.
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20160226_085237_zpsbt3bisyw.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20160226_085237_zpsbt3bisyw.jpg.html)
I'm working on the saddle bag mount / luggage rack, and took this picture for reference. But you can see the windscreen is mounted up, front turn signals, tool tube under the seat, clear stompgrip pads on the tank (I'll be putting black ones on soon), and a little bit of the seat. The seat...... isn't perfectly smooth yet, but I need something to sit on! Did I mention it will be 60° on sunday? Haha.....
Hey man!
Haven't been on in a while, got really bogged down with extensive html classes at school, loving the progress on the 650! I'm gonna start following the build again, what's left at least!
Awesome Rich! The little bit of the seat I can see looks good :D
I love the fairing! It looks so much better than the "modern" fairing on my F!
Mr Sporrer! Glad to hear your busy with school. How's the bike treating ya? I'd guess it's been a little neglected this winter, but that's ok too.
Pete & Rally - thanks fellas! The seat has some pinholes in the filler, and I had a pretty hard time getting it symmetrical in the rear. Not easily noticed, unless you own the bike and have an OCD..... haha. And I made a llittle shroud & lens cover for the fairing too. There's just something about the early GSXR fairings that I really dig.
It's the endurance racer look that wins me over. That "just back from the Bol D'Or" rounded lamp curvy look is all the money
You know you have to follow that up with more pic's Rich :D
Soon as I get my hands on some styrofoam I will be starting to shape a new solo seat pan for the 450 and will be looking at a one piece combined solo seat/tail piece for the Kat... I'm looking forward to it!
In the meantime I need a refresher of the pain I'm going to face :D
What good timing Pete! Took a pic while out on my ride today. I'll add more info later......
(http://i598.photobucket.com/albums/tt70/rmyers104/Suzuki%20GR650%20rebuild/20160228_145039_zpsvetwhsjh.jpg) (http://s598.photobucket.com/user/rmyers104/media/Suzuki%20GR650%20rebuild/20160228_145039_zpsvetwhsjh.jpg.html)
man that thing looks good... :kiss3: :kiss3: :kiss3:
That is a great pic. Just great. That seat looks amazing and so does the fairing. Excellent work as usual Rich, thank you for the update :D
What kind of tank bag is that? Been thinking about getting one...
Thanks Showbiz. I still have some work to do, like the tank badges / luggage rack / etc.. I found out yesterday that my rear brake lever was sticking (needed cleaned & greased at the pivot), and my charging system isn't regulating properly. Nothing terrible, but I'll definitely need to look into that too.
The tank bag is from Nelson Rigg, their CL-2020 magnetic GPS bag. It is HUGE! Fully expanded it will fit my full face Nolan helmet with some room to spare:
http://www.revzilla.com/motorcycle/nelson-rigg-cl-2020-gps-tank-bag
That is a super cool bag. Thank you for the link!
Awesome Rich, just awesome!
That seat/tail looks like it turned out really well!
At first glance you wouldn't even dream it was a GR650... I think you just put the Temptor in Temptor... :D
Cheers Pete! The seat didn't turn out 100% what I was hoping for, but definitely good enough to ride for the season.
I've had this bike "not stock" for so long now, I tend to forget about what it looked like from the factory. So yes, the Tempter is no more..... and the Halfabusa is on the road! Haha....
Well done, good sir, it looks good!
Halfabusa... love it! :icon_lol: :thumb:
I'm mesmerized by the fairing. I now want a modern GSX-R with the fairing from a 1980s GSX-R, somehow. Tail section too.
Great work, orders of magnitude beyond my league.
Thanks man! I was kinda "rushed" to get the fairing done because the GR is my only bike again, and riding season was coming quickly. So it's not at 100% right now, but there's always next winter. The early GSXR fairing was pretty easy to work with - the fiberglass is readily available from Airtech (in many different version btw), and the windscreen is easily found on ebay for under $50.
But for an update: I recently discovered a high pitched "pinging" sound from the motor. Right away I thought it was from pre-ignition / detonation, so I retarded the timing back to stock and filled the tank with 93 octane. After that I was chasing my tail trying to diagnose EXACTLY where the sound was coming from..... but once I pulled the fairing off I saw it: a loose exhaust collar on the header! Years of running the header bolts (not studs) in and out must have accumulated some debris at the bottoms of the holes. So the bolts would bottom out and be tight, but not tighten down the collar. Whew!
That is a close call of sorts. It amounted to nothing but was scary while unfolding. Great outcome.
Wow! New member here and just now seeing this project thread. It is a total inspiration! In one of your posts you said you had taken the fairing equipped bike out and "it wanted to go fast!" I'll be curious to see the numbers once you finish this wonderbike and road test it--especially since you apparently aren't going after more HP. A few years back, I was riding a 78 BMW R80 with and without it's quarter fairing. This fairing had been described in the moto-press as offering "some added comfort to the rider." There was no mention of performance gain with it installed. The R80 and the GR650 have similar HP, and weight. I noticed a big difference in how well it pulled in its mid-range depending on whether or not the fairing was installed. With the fairing off it seemed down about 10 HP. This is the same fairing used on the much faster R90 of that same era. With your more extensive fairing I'm curious about the numbers you get. That is, of course, if top speed is all that important to you. Others have said that HP gain with the GR650 is limited and that the whole package was designed for low and mid range. One of the posts said that the lower end was "not suitable for racing." If that is true, then, streamlining is really the best if not the only answer. Again, really, really nice work!!
Rich, I usually surf the forum at work on my down time, (graveyard shift) my work computer won't load the photos. I'm at home now to see the pics. I really like what you've done, it gives me hope that I'll have a running bike one day too! Keep up the good work friend. :cheers:
Thanks GSteve! I love the old Airheads..... but I'm far too cheap to own one. I sold a 1980 GS450S last year that has many similar design cues as your old R80 - from the tank shape, to the seat, even the quarter fairing. While I can't speak for the cold hard numbers when it comes to performance with / without a fairing, I have noticed that my current bike goes much faster than what it "feels". I remember one of the first rides of the season, I was cruising along a back road where the speed limit was 45mph, and I came creeping up on a car. I didn't think I was going all that fast but I did catch up to them rather quickly and thought "why is this person going so slow?". When I got behind them and matched their speed I looked at my speedo and they were going 55mph the whole time! Back when the bike was in its stock "cruiser" form, my wife and I were heading back from somewhere on a highway (me on the bike, her in her car) and we started playing cat and mouse next to each other. The stock bike would hit 100mph (and it felt like it with the wind resistance), but it took a little while to get there. With all the intake / exhaust / body work I've done, it will hit 100 MUCH sooner.....and it's able to handle that speed much better as well.
Cheers Fink! I use to work steady midnight by choice....now I'm forced to rotate with daylight. The night time is the right time! Haha.... but thanks for the props. I try and tell people: a bike project is actually easy, since you're only working on one bolt at a time. It doesn't happen over night though....
As far as the GR goes, I had to replace a blown fork seal last week. Ordered some OEM seals / dust wipers from Japan, then I noticed my clutch is slipping at high rpms and needed to order a clutch gasket (and pay for shipping again naturally). Since the current bottom end is new for the season, I'll just be swapping out my clutch from the old engine. What else is there..... carbs & jetting. I've had a rich idle for a while now and I'm trying to get that sorted out. I set the float height in the middle of the spec, but I think the problem is that the carbs are slightly angled in the mounts. I've messed with the pilots and mixture screws already so the float height is next. And iI don't know if I've mentioned it earlier, but the tank badges I made are no good. For some odd reason the original tank badge mounts aren't symmetrical - one mount is further forward than the other. Can't really notice it looking from the side, but it bugs me when I look down and they don't match.
Another picture less update....
Ever since I had found out what my "ping" sound was, I started noticing my MPG's going down the crapper. First couple tanks this year were in the lower 40's (not surprising all things considered). Right after the pinging sound, it went to 35 ish, to 30, then down to 25mpg. I was banging my head against the wall trying to figure out what was going on, and at the top of my notes I had "Check odometer for accuracy" since it is an aftermarket job from China. After checking the valves (again), compression (yet again), tuning the carbs (as always), and fitting new coils, I finally started really watching the odometer.....
Bingo! I was calibrating the speedo / odo with a GPS app on my phone and I discovered 2 things: that the speedo doesn't match the odometer, and the odometer was "losing" miles. With the tire circumference set at 925mm, I went 12.7 miles but the odometer read 12.6 miles. Close enough for now..... next trip out the GPS read 34.5 miles and the odometer read almost 13 miles. Way off!
Once I used the GPS to check my fuel consumption, I'm back in the upper 40's.
Ugh, bugger Rich! Cheap Chinese crap... some of their stuff is surprisingly good, other stuff not so much...
I can highly recommend Acewell's gear though, the 450 has had it's 2853 for nearly 50,000kms now and so far so good... will be putting another one on the Kat :thumb:
True story Pete! It can be a gamble.....
So far everything else about the speedo has been flawless. The fact that the entire dash was kinda made around the gauge, and the high cost of an Acewell (especially with all the same features), has me leaning towards keeping the current one for the rest of the season. I can still keep track of my fuel consumption with the GPS on my phone, and the fuel gauge works well too, so I won't be running out of gas by surprise or anything. Besides..... that GS850 tank holds a LOT of fuel!
Life is full of compromises I guess.
At the end of the day as long as it does what you need it to do all is good :thumb:
In our nanny state here you can't afford to have a speedo off at all, you're likely not to have a license too long unfortunately...
It's interesting you say the Acewell is high cost though... with the way things work over here I found them to be pretty well priced compared to a lot of the other alternatives. I didn't really compare with the cheapy Chinese ones though as I was only looking at ones that are certified as ok to use here... we have lots of legal crap to deal with like that :embarassed:
I always forget about how strict your policies are down there Pete.
Weird thing about my current speedo - if I set it up for an accurate odometer (aside from the "forgotten" miles), then the speedo reads a little fast. So in that regard it's just like a normal gauge cluster. The other odd thing is whenever the odometer "forgets" to add miles, the speedometer still works as expected..... which I would have thought the speedo reading would just drop to zero.
Yeah we're a little... over-protected here...
That's weird alright! They must have multiple different circuits in there completely unrelated to each other...