Ive searched around, but the seach function seems a little cheasy, picking out individual letters instead of prhases and words....

so here it goes.   Ive got a 95 500.   Im turning it into a little street fighter bobber.   My goal is to chop 35 lbs off the bike.  Planning to do the basic first.

RU 2970 lunchbox filter, cut the can off and run open exhaust, however I will be welding in a baffle to increase back pressure again.   Im going to rejet to 150, 40, and 2 washers.

Now heres my questions that I cant find.   I plan on cutting out the H pipe section, but haven't seen anyone talk about doing this.   Normally removing H pipes increase power (at least large H pipes that are not flow conductive)... Anyone here experimented wthis?    I know the aftermarket full exhaust has the H pipe removed....   anyone done it on the stock exhaust though?


Secondly, Im going to run 140 70 17 and 120 70 17 IRC rx-01 road winner tires, I want to regear, but I cannot make up my mind.   Should I go to a 44 rear sprocket, or change the front?    And if I change the front should I go to a 14 or 15.    I really havnt seen anyone talk about a 14t and crusing Revs on highway....    Is 14 to much?   

Are the cartridge emulators wroth the 170? 


I dont like the idea of progressive springs, any of you use them?   Are the GS specific springs as soft as the rest of the progressive springs out there?



Also, wheres the best place to buy the air filter and jets?    read cheapest....

I would be hesitant about runnign an open pipe on this bike, or any bike because the law tends to dislike such things.

as for suspension, I'd go with the progressives springs, cartridge emulators, and a revalve kit, oh yeah, and a better back shock too.   if you dont have it, the other thing is a fork brace too, you'll like that a lot. 

in terms of losing weight on this bike, the exhaust is the only place I can see you'd be able to safely do it.   theres tons of aftermarket pipes available you can just slip onto the stock setup(I think) someone correct me if I'm mistaken.

read this one for 14T front sprocket:   http://gstwins.com/gsboard/index.php?topic=28026.0

these ones for progressive springs: http://gstwins.com/gsboard/index.php?topic=38246.40  
                                                http://gstwins.com/gsboard/index.php?topic=37881.0

these one for other/harder springs  www.racetech.com       or directly     http://www.racetech.com/evalving/menu/searchstreet.asp
                                                http://www.sonicsprings.com/catalog/

this one for emulators/other front end mods: http://video.google.com/videoplay?docid=7848723937557327814&q=gs500+katana&total=2&start=0&num=10&so=0&type=search&plindex=0

this one on HOW TO USE SEARCH:   http://gstwins.com/gsboard/index.php?topic=26157.0

have fun
KaMeL


                                               

Got progressives and 15w oil.It's great.The Vance and Hines exhaust doesn't have the cross pipe,so removing it shouldn't matter.IMO I'd do a 14t front sprocket.As far as dropping 35lbs let me know how you do it.I'm building from the ground up an wanna keep it light.

Your other questions are answered.

For the dropping 35 pounds part, it's gets interesting.

1) remove the gas tank. it's a good 10-12 lbs empty, and @ 6lbs / gallon for liquid, figure another 24 lbs for the fuel you won't have and install a 1 1/2 gallon ballistic plastic jobber under the seat, forward the rear fender.
2) K&N filter, that should be good for 1/2 lb savings over stock.
3) Sawzall the stock muffler off. Weld in a baffle/sock/whatever that should be good for another 5 lbs.
4) Find a 'racing' supplier for motorcycles. Replace all your bolts/nuts/axels/connecting rods with titanium. That should save you 10 lbs or so.
5) I've heard there are titanium chains and cogs too, but never seen one myself.
1-4 should only cost $1000-2000 USD.

OR

You could just drop 12 lbs of body fat, replace it with muscle, and be amazed at how 'light' and 'flickable' your gs suddenly is. It's cheaper too.


I really can't imagine it possible to shave 35 lbs off the gs and it still have a frame. There is very very little there to begin with. Compare a gs to your typical bagger, and show me what can be chopped off. I might be surprised.

Yea the only way your going to shave enough of the GS is to have a solo tail, so chop the end of the subframe off completely and just have a solo seat. Reduce the tank size. Other than that nothing else can really be done, its a cheap bike and beginner bike built on an absolute budget, they have left off everything they can possibly, and kept weight down to increase performance.

So yea thats a hard task your basically guna have to build a new bike, the way to really do it though would just be stick a new engine in but you would lose performance to get a light enough engine.

Anywhos....


ohgood - muscle weighs more than fat, a fair chunk more. Hence why nearly every worlds strongest man is considered clinically obese for their height and weight measuring in the conventional way. Thats why they measure BMI (Body Mass Index) - indication of how much fat you are basically far more accurate measure of health.

I have a solo tail,and aluminum swing arm.Saves a few pounds.

Just increase the performance to counteract the weight you can't shed.

<------------------ Fit a power commander

OR, you can do something simpler yet, although it'll cost you around $8-10k.  go out and buy a new CBR600RR or ZX6.  (sorry, GSXRs are just ghey)

For one, I'm a welder, and Im about to go out and buy a new TIG for pre Xmas for me.   Ill be needing to try it out.   

Guys I apprecieate all the comments....   Let me add/modify to what has been said.

1 the entire rear "subframe" will be coming off and replaced.   Replacement will be as minimamalistic as it gets with no fairing, just a small seat and a carbon fiber light bucket ill be making.  I esimate about 10 - 15 lbs will be lost doing this

Replace the rearsets with gsxr ones... 4 lbs.

I would like to replace the swing arm with the aluminum gsxr one, however Im somewhat agaisnt it due to the weight gain from larger rim and tire....   Undecided.

Cutting the muffler off has to save more than 5lbs.... I estimated about 7.  I dont like obnoxiously loud exhausts, which is why I will be welding in a baffle, however if that is still to loud I will be adding in a under frame (buell style) resonator

Ill be moving to a 14 tooth front sprocket I guess, thats 2 less teeth.... estimated .02 lbs...  that will help.

Naturally the centerstand will be removed.... 3-5 lbs?

and I am 5' 11" and 165...    not to much to loose there....   


4 more questions now.

Someone with experience guide me toward progressive or straight rate springs though....    can anyone estimate a good rate for 165lbs?


I have to replace head gasket, so I want to shave the head while im at it.   I believe i can go up to .050"     I would like to go .030"..... is this a good safe number or can I go a little further safely?

I do 2 stroke jetski stuff, so I know about porting, but on this specific motor, what do you do to the exhaust port?   Just a polish for good exhaust gas exit velocity or is diameter actually changed?

and lastly,


where the hell do I tap into the block for an oil cooler??   

Thanks again.

Well if you are going to add the gsxr swing arm you might be able to buy carbon fiber rims  from bst.  You didnt mention prices thats why im throwing this out there.  They are a company out of south africa that makes carbon fiber rims for a bunch of differnt bikes.  In fact they just finished their triumph line and are working on their bmw ..  But if you wanted to spend the cash and save the weight this would be one way to do it.   I would also recomend  chopping off the turn signals  and removing the metal headlight for a lighter plastic one.  Drop the chain guard and mud flap  YOu could also fabricate aluminum dog bones and engine cradle.  Along with possible triple tree. chop the front fender down.  If you really wanted to get crazy  You could eliminate the back brake system all together.

But whatever you do good luck. 

Quote from: Foximus on December 08, 2007, 08:46:27 AM
1) [...] and I am 5' 11" and 165...    not to much to loose there....   [...]

2) [...] Someone with experience guide me toward progressive or straight rate springs though....    can anyone estimate a good rate for 165lbs? [...]

answer 1) actually you could work on it a little bit      I'm 6.0 and not even 150     damn! I tried to gain weight but not much works for me...

answer 2) http://www.sonicsprings.com/catalog/calculate_spring_rate.php?osCsid=0e443c5d2a6d9dc6f796013c94eed922
it's sonic's official web site and you can calculate your spring rate over there.

good luck
KaMeL

Yea I saw the spring rate calculator after I typed that.... Im gonna go with a sonic spring 80kg.

As for the aluminum dog bones and engine cradle thats a great idea and easy to make, thanks for that.

Chopping the turn signals... lol  they are just little LED clusters...   Front fender may or may not stay on... havnt decided yet...   and again the rear will be completely chopped off.   Not even a solo tail, just a seat.

Still wondering on the head shaving, porting, and oil cooler questions though.

Quote from: Foximus on December 08, 2007, 03:13:29 PMoil cooler

Oil filter relocation kit? I know they exist for cars, i have read somewhere you can make them fit bikes. Then just plumb a cooler inline.

James

Quote from: Anakist on December 08, 2007, 10:33:51 PM

Quote from: Foximus on December 08, 2007, 03:13:29 PMoil cooler

Oil filter relocation kit? I know they exist for cars, i have read somewhere you can make them fit bikes. Then just plumb a cooler inline.

James

It would take a whole lot of machine work to move the oil filter outside of the engine and/or add a oil cooler.If you want an oil cooler just buy a GS500F engine with an oil cooler.

hrmmm....    theres gotta be some way to do it easily.... but reguardless, thats not to important at this point in time.    I just figured Id get all my questions out at once.


Anyone got info on whats best to shave the head?   .010" is roughly equal to 10psi and a 30 psi increase is pretty good for power.....    I just dont want to have to get dished pistons to clearance valves.

Shaving the head, porting and all of that- why not get a 2smoke ?

It just hit me you're making pretty big changes, when a 2smoke would have less weight and more power without having to change much.

The oil cooler and filter relocation makes me wonder if you're planning on making this a 'stunt' bike, also.

Well.... I wasnt the one who brought up the oil filter relocation kit... I just wanted an oil cooler,   But more or less Im going to try to turn this into a track bike.

If it were me, and i had my druthers I would have bought a two stroke.    I know much more about tuning them.

Well... I just pulled my springs to inspect the shocks and whatnot.... turns out I already have progressive springs.... So I deffinately want a much more stiff straight rate spring... i didnt like how the front was already....     

Anybody wanna buy a set of progressive springs?

Also, the spacer was missing.    How long is the normal progressive spacer length?   an inch correct?

do the gsxr or kat front end swap.  if you going to use this as a track bike like you say then the two rotors up front and the four piston brakes that come along with them will make a huge difference on the track