We are getting there...installed new globes with coloured silicon caps to bring out some more colour into the light..not a bad effect. Ordered some more parts. New air filter, new dampers for behind the guages as they were cactus and perished and the relevent wire fasteners for the cables also fitted a horn I had from the old bike that still works...now to find the wires for it...mmm


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New leds in instruments engine and nuetral. Just need the others and we are set


Fingers over lamps to give a clearer indication


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Got most of the harness inside the light housing. Very happy with the outcome.

Now my starting issue....screwdriver across starting relay kicks her in the guts...so the relay is ok? No action via the starter button. The power to the button is all good via a check using a light probe. Also same for kill switch..

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... So there's a break or melted wire/plug down on the other end of the circuit..closer to the starter? ... Trace that wire colour down the harness and find the 'section' that is dead ! 

Clutch safety switch is in series with the starter button.
are you pulling in the clutch? or have you bypassed the safety switch? Broken safety switch? Not connected?

Remember a bike must be in neutral OR the side stand up for it to run. That's a safety circuit so you don't ride with the side stand down.

Ok here is where its weird...there is no plugs on the clutch safety switch on the lever..never had any before the pulldown and it started prior....now what are the wires that run to that switch ? I can look later via the manual but if u guys have a heads up it will be a bonus haha... Ive reconnected everything in the light housing according to hits colour. Got the horn working indicators..park lights tail and stop lights all work. All power to those aspects are working aok... Going to do chain and sprockets then rassemble today then attack this electrical bug...grrr

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The previous owner had bodged the fuse..had copper wire with two wedges in there obviously blowing fueses he was...it started then..but since I put in a 20amp it doesnt fire nor does it blow it at any stage....sooooo weird

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...hmmm... someone correct me if im wrong... but was looking at clutch safety switch last evening... a thin black wire .. and a thin black with yellow 'tabs' across it ??... i think?... should be hiding in the sleeve which as the left cluster wires in it?

Mmm will have a look..cheers bud

Some more done today.
Painted headers



Front wheel assembled


New Rear and front sprockets. Old front one was a 17 and in good nick once cleaned. Chain cleaned and rear wheel regreased shaft and reinstall. Going to give her to the shop for bearings as I dont have the tool and dont want to spoil the spacers.

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Quote from: Golly on August 07, 2013, 12:27:53 AM
Painted headers

What did you use to paint the headers?

Wups my bad.... Thought to look again.... BOTH wires are thin black and have a yellow stripe ... Without pulling the cluster apart it looks like they enter into the edge of the cluster 'pod' at the very end of sheath and then exit back out to the safety switch... Shows how good 'memory' is.. 

... Buuuuut ... I have a k6 F ... If you have a 90 'EN' (US) model .... Then according to the Haynes wiring diag ... If you have a standard 90 harness..

Hmmmm... Picture makes a thousand words ....but how many words to convey a picture? ..

...on right side ... Starter switch has orange with white stripe coming in from kill switch ... Then out to yellow with green stripe , which leads across harness to a inline 'resistor?' .. Still yellow with green stripe into another 'resistor?' Then into the starter relay ... Other side of starter relay is on solid black wire to starter motor plus a black with white stripe which is the common 'bike wide' negative to battery...

... Also ... The position of the clutch safety is different in the diagram ... My k6 diagram shows the switch as in the harness wire bundle along with the left cluster switches ....I think ... But your 90 diag shows it as 'located' not in that actual 'bundle' but more like down 'near' the starter relay? ...

But this could be just for the diagram.... Otherwise the clutch safety switch is located down near the other end of the clutch cable near/in the entry to the gear case? ... I've never looked at a live 90 era bike so I don't know the real physical location.... It would make sense to still locate it on the lever ... But the diagram makes it ambiguous ... So definately confirm with one of the 90 era owners here just where the safety switch is located...

I don't mean to make it confusing for location... Just most wiring diagrams I have looked at in my amateur viewpoint do usually show 'roughly' the location in the 'laid out flat' harnesses...

What did you use to paint the headers?
[/quote]

VHT Extreme Heat matt Black, then VHT Extreme Heat clear coat over the top to bring out the colour, the matt is very matt and quite dull.

Front pads installed


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nice bike
couple questions/observations
that frame is WAY to clean to have 33clicks on it and you said you didn't paint it.
the swingarm looks stock paint.... black was not a 90 option
the wheels look stock paint... black not option in 90
engine looks like it had bottom end replaced.... already noticed on page 1
you got the kewl stock clip-ons NON-USA
when you take the carbs apart do they have stock adjustable needles?

your workmanship looks good.  keep it up

Haha this bike is 90 via the vin on our national register..might go into suzuki for conformatiion on it. It was red..little bit shows under the tail piece. Also wheels were white as you can see via the chips on the hub on the front wheel. This bike has been built from a collection of bits as Im still figuring out what actual year it is.  GOOD NEWS!!!!! BRAIN FART MOMENT i had the 4 pin black relay into the wrong white connector. Sucks having two 4 pin adapters in the same area lmao!!!!! Good thing is she kicks over via all switches...now to give it some fuel...some reason it back fired a little then just kicks over no fire yet lolol

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New look rear



New look front


New gauge dampers thks to mick hone suzuki in oz. Great service




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Looks great

Good job Chap!

Bit of a dampener today, got it all together, battery charged up, and what happens......  fuel comes out of the airbox down the overflow tube, so I have a float issue or a blockage somewhere.  This gives me an excuse to do a couple of things.

1.  Tank is off, rust inside, so a good clean, a petcock rebuild and prep for spray.
2.  Give both carbs an overhaul and new bits!!!
3.  Whilest carbs are off, take out motor and add new Suzuki plates and respray the motor.
4.  What the hell, whilst the motor is out, may as well do the frame as well.... sooooo a minor blockage has caused
me to bite the bullet and give this 23 year old bike the love it deserves.

hahahaha... 

So this is my first carb strip down, so far not so good hahah.. noticed a couple of things and hope they are fixable, I have alot of questions, dont hate me lmao!!

Shitty carby


Inside...


This is my first issue, these suckers are solid stuck and PO has hacked them up obviously.  How to get out and what replaces them haha...


Second issue, this is not normal no doubt... also, any tips on how to get that snapped piece inside out, I dare say I can order a replacement.


Carby Model for ordering spares


I have read somewhere that these are aftermarket since there is five settings ?? Is this true ? its on the fourth clip


120's.... normal ?


Need new ones, PO farked this one and I just got it out..


After a clean, starting to look good



The clean side of the bench, nice white nappy hahahah