This is my steed, it's a 1991 with 25k on the clock, previously rebuilt from frame by previous owner and didn't quite do a good job of it. It has a newer motor in, from a 2003 or something with 10k on.

My first plans were to fully cafe racer convert it. But I'm just seeing how it turns out.

Here is how it started:



Current progress:





It got an advisory on the MOT (which has just expired) for failing fork seals, actually they leaked really badly to the extent it affected the front brake... So I bought some new forks with fresh seals in for £40, stripped the brake down and completely decreased the entire front end.

I also bought some CNC aluminium clip on handlebars and removed the clocks, maybe keeping it that way... We'll see.





One of my close friends gave me an MTC exhaust that was made for a bandit 600. I modified the link pipe to fit and gave my Remus manifold a good polish up.





Starting work on the rear end I bought myself a DID X-ring chain and sprocket set and began to strip the suspension down and stripped the paint off the swing arm.

Got some 5mm longer dog-bones which should Jack the rear up by 25mm.





Here is the front end set up



Painted the back of the headlight, mudguard, bracket and yellow tinted the headlight.



Fitted fresh brake pads front and rear and replaced the tyres front and rear. A few little things to do on it, like paint the tank, paint the swing arm, paint wheels, change the oil and filter, spark plugs, but they're all ready to do. Once it is on the road I will be taking it to a friend's garage for the use of his welder to re-do the subframe.

A lot more to follow!

sub'd! 

I would look into a katana 600 rear shock, would raise it about the same but also a good upgrade from stock..gs suspension is wicked soft. I am about little more than 14 stone though

Yeah I considered getting one but money is a little tight and I just want it ready for the road now. It's simple enough job to do when the time is right.

I've finished painting the swing arm, linkages, brake torque arm and fitted new pads.

Went to fit the chain, thinking it was a spring clip split link but it's rivet type so I've ordered a spring clip typ as I do not have a rivet tool.

Actually not sat on bricks now!





I've also got a question regarding the front sprocket, is there meant to be a spacer between the sprocket and the engine casing or is it just circlip and sprocket?

Thanks

there is a captive spacer but unless you took the cush drive off it should just be sitting in there still. It is looking good sir

Quote from: MARider on July 02, 2014, 06:25:10 PM
there is a captive spacer but unless you took the cush drive off it should just be sitting in there still. It is looking good sir

Thanks! Cush drive? As in rear wheel? I'm talking about the front sprocket?

Front end is done! Exhaust is on!







Unfortunately my chain is slightly too long and the battery isn't holding charge (gel battery). I had it on charge for a while over night and the Oxford charger indicated that the battery was ready to use :S

Battery ordered, oil, filters and plugs changed, battery on its way, new pegs fitted, 12v power outlet and water proof sat-nav bar mount on its way, all coming together nicely. Started it this weekend and it sounds heavenly.

http://youtu.be/GhJHQzS97D8

At least the easy starting with none (or very little) choke is a good indicator that the jetting might still be okay with that exhaust on.

Nice looking bike mate, liking the look without the rear plastics!

Thanks mate! There's still a lot of work to do on the rear end, basically taking the frame under the seat, moving it in and up and I'm going to fabricate some form of luggage mount which I'll be able to unmount with reletave ease.

Need to either find a different place to mount my electrics or use either some stainless sheet or some plastic sheet and panel it slightly.

I fitted some new rear indicators too:

All legal and on the road as of 6 hours ago, haven't been off it since!
Sounds fantastic, feels fantastic, admittedly it's going to kill my wrists xD



More pics and maybe videos to follow.