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Main Area => Projects / Builds, Racing and Tech => Topic started by: Henxo on November 16, 2017, 07:17:05 AM

Title: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 16, 2017, 07:17:05 AM
Ok so i bought my Suzuki gs 500 (2000 model) for 450€ as a nice project for me. Bike runs fine (at the moment) time to get chopping!!! Any ideas/suggestions are more than welcome.(https://uploads.tapatalk-cdn.com/20171116/23fa6c9fd4781988f91b8a616b230ccf.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 16, 2017, 07:18:29 AM
Rear break pads, oil and oil filter first.(https://uploads.tapatalk-cdn.com/20171116/85b3ec2e86212b370727ece8d4cbb6b9.jpg)(https://uploads.tapatalk-cdn.com/20171116/f0a89174a5c7f35ffb82b9849f1c0998.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: cbrfxr67 on November 16, 2017, 07:47:18 AM
Sweet!  more pics!  Cant wait to see what you come up with.  Are you going to make it project or going to ride it and work on it at the same time?
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 16, 2017, 12:43:18 PM
Quote from: cbrfxr67 on November 16, 2017, 07:47:18 AM
Sweet!  more pics!  Cant wait to see what you come up with.  Are you going to make it project or going to ride it and work on it at the same time?
Want to ride and work at the same time...still working on my lisence too so ive got plenty of time to work on it before i can even ride It legally.


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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: The fink on November 16, 2017, 08:41:54 PM
Congrats on the purchase. Excited to see what you do to her.  :cheers:
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 18, 2017, 04:33:38 AM
Ok so just got some bits in that i needed...60€ for all 3...i think its not too bad...theyre not perfect but a bit of paint should make them look better. Got the handle bar bit so i can put normal handle bars on...any suggestions for the handlebars? Thanks.(https://uploads.tapatalk-cdn.com/20171118/b773c729aa5515a3f13ac216cc7f1571.jpg)(https://uploads.tapatalk-cdn.com/20171118/40174198f89673e21ac44cd7118d2903.jpg)(https://uploads.tapatalk-cdn.com/20171118/d417342b0b27ed924dfe63e6cb1b8a39.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: ajensen on November 18, 2017, 10:28:05 AM
Handlebars may be the most personal choice on a motorcycle. Since you do not have a fairing, I suggest something reasonably low. I find that higher bars, unless there is some sort of windshield, make the arms tired because the rider is always fighting the wind. On the other hand, lower bars have the rider leaning into the wind. No matter what, whatever works for you is the right choice. It took me a while to get used to the stock bars on my GS500f, but I really like them now.
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: gregjet on November 19, 2017, 01:22:06 PM
I am beginning to think all the GS500 's in the world have engine side covers like that. I put carbon fibre over mine because they were so scratched.
Renthal ultralows bars have the advantage of absorbing vibration to some extent.
Rear brakes also seem to be a GS thing. Though mine had one pad completely missing and had eaten the rear disc.
I await developments.
Have fun!
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 19, 2017, 01:52:04 PM
Quote from: ajensen on November 18, 2017, 10:28:05 AM
Handlebars may be the most personal choice on a motorcycle. Since you do not have a fairing, I suggest something reasonably low. I find that higher bars, unless there is some sort of windshield, make the arms tired because the rider is always fighting the wind. On the other hand, lower bars have the rider leaning into the wind. No matter what, whatever works for you is the right choice. It took me a while to get used to the stock bars on my GS500f, but I really like them now.
👏👏👏

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 19, 2017, 01:53:00 PM
Quote from: gregjet on November 19, 2017, 01:22:06 PM
I am beginning to think all the GS500 's in the world have engine side covers like that. I put carbon fibre over mine because they were so scratched.
Renthal ultralows bars have the advantage of absorbing vibration to some extent.
Rear brakes also seem to be a GS thing. Though mine had one pad completely missing and had eaten the rear disc.
I await developments.
Have fun!
Should be fine when i Paint It...not looking for "perfect" anyway.

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: qcbaker on November 20, 2017, 05:27:07 AM
As far as handlebar suggestions go, like ajensen said, its really a personal preference thing. How do you like to ride? If you want a more relaxed ride, get something more upright. If you want a sportier feel, get something lower. I have the Bikemaster Superbike bars, and I really like them.
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 20, 2017, 07:01:55 AM
Quote from: qcbaker on November 20, 2017, 05:27:07 AM
As far as handlebar suggestions go, like ajensen said, its really a personal preference thing. How do you like to ride? If you want a more relaxed ride, get something more upright. If you want a sportier feel, get something lower. I have the Bikemaster Superbike bars, and I really like them.
Yeah not sure yet...wont be doing much travelling so looking for It look nice rather than being practical 😂😂😂


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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 21, 2017, 11:43:19 AM
Cafe Racer style seat arrived today for when i chop the back end...only 30€ and i think It will do the job fine...and probably wont find anything cheaper!!!(https://uploads.tapatalk-cdn.com/20171121/76a3d720d7551f562da9424379d213de.jpg)(https://uploads.tapatalk-cdn.com/20171121/f0c35e3ca6227ca1cff7affa8f90395d.jpg)(https://uploads.tapatalk-cdn.com/20171121/393010909ea4601a14e76a96abc060c5.jpg)(https://uploads.tapatalk-cdn.com/20171121/c782a8ee67d2d3dad8fadd44b179c831.jpg)(https://uploads.tapatalk-cdn.com/20171121/5652d7db6ea0dc84df86ef578c7dd7fb.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: saxij on November 21, 2017, 07:23:38 PM
oh sweet I'm also in the process of building a cafe/scrambler from a 2007 gs500f with a blown engine.  I'm taking my time with it, working on rust repair, cleaning/lubricating bearings, powdercoating a few parts myself, and keeping my eye out for an engine before I start chopping. :thumb:
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 21, 2017, 11:23:42 PM
Quote from: saxij on November 21, 2017, 07:23:38 PM
oh sweet I'm also in the process of building a cafe/scrambler from a 2007 gs500f with a blown engine.  I'm taking my time with it, working on rust repair, cleaning/lubricating bearings, powdercoating a few parts myself, and keeping my eye out for an engine before I start chopping. :thumb:
💪💪💪💪

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: J_Walker on November 22, 2017, 08:00:11 AM
The only way you're getting the GS bars far back enough for a proper upright comfortable position in my opinion, is by getting blocks to raise the bars and getting bars that are further back, but will require longer brake lines and clutch cables, and throttle cable, and choke. a real PITA, my advice for more comfort on the GS, is to actually make the bars lower. maybe it's just my oddly long torso though.
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Ne0n on November 22, 2017, 11:50:58 PM
So I've been through 5 different types of handle bars on my GS by now (original, clip-ons, superbike, dragbar, mx bars), and for my riding style the mx bars are the best.

It's something most people don't even consider, but I'd give it a try.
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 23, 2017, 02:45:05 AM
Quote from: Ne0n on November 22, 2017, 11:50:58 PM
So I've been through 5 different types of handle bars on my GS by now (original, clip-ons, superbike, dragbar, mx bars), and for my riding style the mx bars are the best.

It's something most people don't even consider, but I'd give it a try.
Photo?


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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: mr72 on November 27, 2017, 12:51:19 PM
Quote from: Ne0n on November 22, 2017, 11:50:58 PM
So I've been through 5 different types of handle bars on my GS by now (original, clip-ons, superbike, dragbar, mx bars), and for my riding style the mx bars are the best.

It's something most people don't even consider, but I'd give it a try.

I have KX-bend MX bars on my bike, aluminum, they're pretty fab. It's the third handlebar I've tried. It all depends largely on your body type, how long your arms and torso are, etc. This isn't really about appearance.

I might not mind if they were 1/2" or 1" taller. But they're pretty close to perfect.
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on November 28, 2017, 09:19:49 AM
Just sold my 2001 Kawasaki kx 250 so new bits will be on the way pretty soon!

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: mr72 on November 28, 2017, 01:12:19 PM
Just remember a KX handlebar on a KX250 is going to be quite different than one on a GS. The top triple clamp is probably much higher relative to the seat on a KX, and the seat is probably also much closer to the fork. So a KX bar on a GS will feel quite low and you will lean over a lot. I think the stock bar might be 1" taller and have a lot more "pull back" ... that is, the angle of the grip portion of the handlebar is much shallower which positions your hands much further back.

So the KX bar will work great for you if you have long arms relative to your torso length, and you are in the taller-than-average range. If you are average height (say, 5'8") with average length arms then the KX bar will probably feel very wide and like it causes you to lean forward a lot on a GS. In that case I am guessing a Daytona bar will be much more comfortable.
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on December 01, 2017, 05:27:30 AM
Quote from: mr72 on November 28, 2017, 01:12:19 PM
Just remember a KX handlebar on a KX250 is going to be quite different than one on a GS. The top triple clamp is probably much higher relative to the seat on a KX, and the seat is probably also much closer to the fork. So a KX bar on a GS will feel quite low and you will lean over a lot. I think the stock bar might be 1" taller and have a lot more "pull back" ... that is, the angle of the grip portion of the handlebar is much shallower which positions your hands much further back.

So the KX bar will work great for you if you have long arms relative to your torso length, and you are in the taller-than-average range. If you are average height (say, 5'8") with average length arms then the KX bar will probably feel very wide and like it causes you to lean forward a lot on a GS. In that case I am guessing a Daytona bar will be much more comfortable.
I havent put the kx handlebar on...ive sold the whole bike!

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on December 01, 2017, 05:29:14 AM
Exhaust painted with high temp paint. Pipe was only on with 2 bolts...other 2 are snapped off and stuck in there. Any ideas about removing them?(https://uploads.tapatalk-cdn.com/20171201/ad97a0a230f12564f16abc6003b87c80.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: J_Walker on December 01, 2017, 11:06:15 AM
Try to soak them in PB blaster, or hitting them with a pretty beefy torch.

then trying to "unscrew" them with a punch if this doesn't work, time for a EZ-out type tap. Ace hardware carry's some irwin ones that come with the proper sized drill bit. I find you're less likely to "snap" an EZ-out style bit, if you drill a pilot hole for straightness, then use the provided drill bit. then measure the EZ out at the widest point, use a drill bit just ONE size down from that. and drill about 1/2 way the depth of your hole. deeper your EZ out is, the least likely its gonna snap.
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: cbrfxr67 on December 01, 2017, 02:07:34 PM
Pics of the one under the tent?  :D
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on December 01, 2017, 06:39:38 PM
Quote from: cbrfxr67 on December 01, 2017, 02:07:34 PM
Pics of the one under the tent?  :D
Nice old Harley....(my dads) sigh....

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on December 07, 2017, 05:44:30 AM
New sparkplugs in (NGK)
New handlebars arrived
And mini indicators(https://uploads.tapatalk-cdn.com/20171207/4c60e3052b19dbf74388da90e2559b8d.jpg)(https://uploads.tapatalk-cdn.com/20171207/4c64fe760c7fe5cb1ef45728ab8a901f.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on December 07, 2017, 07:23:59 AM
New muffler(https://uploads.tapatalk-cdn.com/20171207/9e4be86c470de3c228797878e752cf20.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: cbrfxr67 on December 07, 2017, 10:45:28 AM
sweetness,...can't wait to see installed!  no pics of old Harley? :cry:
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on December 11, 2017, 05:55:23 AM
New tail light....road legal even though its so small 💪(https://uploads.tapatalk-cdn.com/20171211/b444a8a754dbc50ad7374e2367b4bda7.jpg)(https://uploads.tapatalk-cdn.com/20171211/50444bc39946603c8e2a48bbc40b493e.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: ajensen on December 11, 2017, 08:58:09 AM
Cool
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on December 11, 2017, 10:05:27 AM
Bates style headlight
New gripa
Lisence plate light
Fork gaters(https://uploads.tapatalk-cdn.com/20171211/4e1fa50228d6ad7ed2cd6ca56c5dfc67.jpg)(https://uploads.tapatalk-cdn.com/20171211/efb9591e3f6007d0bb18beda2d48d218.jpg)(https://uploads.tapatalk-cdn.com/20171211/6797fd867cd9c7571959d37a1377a7a6.jpg)(https://uploads.tapatalk-cdn.com/20171211/3cdc8ba4d3e22fe7d688b8a96769a200.jpg)(https://uploads.tapatalk-cdn.com/20171211/a9d638e1b9271bab2c1277b6bf6a07cc.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: ajensen on December 18, 2017, 11:53:51 AM
I am eager to see the final product. I like the retro look of the headlight and fork rubbers.
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on January 15, 2018, 06:49:30 AM
😵😵😵(https://uploads.tapatalk-cdn.com/20180115/23ca504f9c204c6bb0580ba5a5dea077.jpg)

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: cbrfxr67 on January 15, 2018, 08:47:04 AM
update pic sweet!  what's next?
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Kenner on January 15, 2018, 03:13:45 PM
Quote from: Henxo on December 01, 2017, 05:29:14 AM
Pipe was only on with 2 bolts...other 2 are snapped off and stuck in there.

Hey Henxo,
How did you end up getting those 2 stuck screws out? I had the same problem and after trying a number of solutions that failed I just ended up drilling the two stuck screws out.

Ken
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on January 16, 2018, 12:06:02 AM
Quote from: Kenner on January 15, 2018, 03:13:45 PM
Quote from: Henxo on December 01, 2017, 05:29:14 AM
Pipe was only on with 2 bolts...other 2 are snapped off and stuck in there.

Hey Henxo,
How did you end up getting those 2 stuck screws out? I had the same problem and after trying a number of solutions that failed I just ended up drilling the two stuck screws out.

Ken
Yeah used an extractor kit 👍👍👍

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: Henxo on January 16, 2018, 12:08:12 AM
Quote from: cbrfxr67 on January 15, 2018, 08:47:04 AM
update pic sweet!  what's next?
Sorting the back end out at the moment...cleaning all the cables up so you cant see anything...cut end off and make a seat out of fiberglass and then get it covered...

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Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: cbrfxr67 on February 02, 2018, 02:23:02 PM
Then what happened?
Title: Re: CAFE RACER/SCRAMBLER PROJECT
Post by: TheCheese13 on February 18, 2018, 07:04:11 PM
Dirt bike bars work and look well on it. I went with bikemaster Euro handlebars