i'm getting some new drill bits and am trying to get the mounting for the headlight down today.

pictures later

it has been raining lately so not much new to report.

by recommendation by dgyver i removed the tach drive and found a suitable plug. i used a plug for an O2 sensor bung from an after market subaru downpipe. it was perfect





reinstalled:

NICE!  I was wondering how to fix that tach fitting after I installed my vaypor gauges!

Gotta love it when things like that O2 sensor plug work out so nicely! Great mod and thanks for the writeup.

STEERING STOP writeup:

START OFF by cutting/grinding the GSXR tabs down on the triple.

ok; now for the 'new' steering stop... the GSXR lower triple has a reinforced area, visible from below. using a 25/64" drill bit (or a 3/8" then enlarging later). I've decided on using a 10mm bolt (actually it's the upper bar clamp bolts) so the 25/64" bit is as close to the measured 10mm bolt dimensions as you can get.  The idea is to drill a hole through the reinforced area on the triple, stacking a bunch of 3/8" washers and pass the bolt through creating a new stop. The hole is located on a shorter radius than the GSXR stop and the washers give some distance radially from the bolt for the stop to interfere.





as seen here...it is already threaded


here it is drilled out and on the biks



again...it's easier if the gsxr tabs are already cut off




more on this later; it's raining



UPDATE:

Grind the old stops off (should take care of this at the beginning)


Using the old triple clamp bolts (since they are m10 grade 10.9 ...or wait...12.9? i'll have to double check) and 3/8" washers. this will act as the new steering stop.









full lock right


full lock left

IGNITION:

you need to separate the the old ignition cylinder from the top triple of the GS. it's a pain in the ass if you don't have a dremel. You can drill it out (like i did) but be prepared to score up  the bottom of the unit...i for one don't really care.

once the cylinder is removed, USE THE SAME 25/64" (or 3/8") drill bit to widen the holes. Using some hex socket cap screws (allen head) bolt it right up to the GSXR upper clamp. everything fits fine, and the steering lock will STILL work with NO modification so long as it's positioned to the left (like mine) or in the center (like some gsxr1000's...or stock GS configuration)

the ignition in the center will allow the steering to lock with the wheel cocked right. The ignition on the right will lock the wheel dead straight.

sorry, not many pictures of the process

Glamor shots installing the wheel. Brakes are bled.

after installing the axle:




gotta tighten it; so i used a nut and bolt to hold down the hollow end:



tighten down axle nut to 72.5 ft-lb; Pinch bolts 18 ft-lb:




i thought the gold forks would be mismatched to the bike's colors, but the rear shock and the chain have gold color too. It would have been nice to get a set of rotors with gold centers.

Is the front wheel an 18? It looked bigger in the comparison click.

Quote from: average on May 29, 2009, 01:02:58 PM
Is the front wheel an 18? It looked bigger in the comparison click.

it's a 17, but wider. I'm using a 120/70 r17 front tire

\

That front fork setup is awesome!  Really makes the bike look aggressive.

Nice work. 

great job! bike looks insane!!

wow looks great!

Ignition lock - to get the GS one out, I cut the thread bosses out of lower triple. Who cares, there is a million of those I have ... when I used to drill it out it would take longer and I had a perfect lower triple, now it takes 20 seconds and I have a nice ignition lock and a destroyed lower triple.
Cool.
Buddha.

but but but....i'm trying to preserve as many parts so i can sell them (futile attempt because no one buys this stuff) to make up some funds to ship the wheel to you!!!!

Wow wave rotors?
How fast does the bike stop?

took it for a test run and it stops well; however i have not bed the pads in nor have i taken it on the highway. I'm going to bleed the master once more now that it has sat for a couple days. the brake lever feels a LOT stiffer.

i'm still waiting for some t-bolt clamps to fab something up for the headlight

<duplicate post>

Okay, I get the steering stop idea but is that really enough turning radius for the bike? Have you rode it yet? 

MOUNTING THE HEADLIGHT:

I am still broke until you gracious folks buy some stuff from my for sale thread (in my sig)...but i came up with an easy way to mount the headlights using some of the old hardware (i'm reusing as much as i can here from all my leftover parts since i'm on a budget)

I bought some 2" T-bolt clamps for about 2 bux and change each.... and modified the stock headlight brackets

This also made it easy to keep the turn signal mounts


stock brackets:


Drill holes in the impressions from <tac-welds?>:


Example:


Cut the old fork tube tabs off:


Done


I chose to use some adhesive foam and a rubber..thingy as bushing so it wouldnt scratch the fork. it looks a bit ugly but hey...8 dollar mounts


Test fit:








Headlight is mounted up.. all is well but i don't have a pic yet...i went to the beach instead


more later...