Short story; bike sold in 2008 and PO crashed before reaching 300 miles on the clock. Nothing serious, he drove bike back home, Cracked fairing, bent radiator and etc. Parked bike for a while, disassembled fairing, attempted some repairs but never actually rode again.
My story and this bike starts couple months ago. I have 1999 ZRX1100 that I started overhauling about that time. Trusted Kawa developed cold cylinder after I let it sit when I was contracting out of state and not riding. As I was taking it appart and ordering / receiving fuel system parts I realized it is going to take me a while before I will have bike where I want it. Wanted to ride bad and Started looking for quick project bike or even something new. This is how I stumbled on this slowsuki. Not that I was particulary looking for 2cyl after coming down from four but heck how often do you pass on brand new used bike? It is a liter bike it can't be that bad.
Big weekend, one year bike anniversary and review.
I got the bike year ago and happen I needed new tire and oil change. Bike has 3600 miles. Killed original Michelin about week ago. I had Shinko Raven 09 alredy waiting but bike stands and spools were on order. short story I didn't get rear sland on time and I had to improvise with stuff laying around in the garage. Worked so well I do not need stinking stand anymore.
Removed the wheel and let local shop change the rubber. It was 29 dolars , but after seeing 4 of them fighting the tire for one hour I feel money was well spent.
Cleaned and lubricated chain drive and cleaned and lubed rear caliper. Some with axle spacers and adjuster plates....
First World problems are killing me. New phone no image resizer, instaled resizer, unable to upload resized images to hosting website... rrrrrrrrrrr
So much bull with this, looks like hosting site is messed up and nobody is home
... finally I made albums on SV Portal and run links to my pictures here.
Working TL1000s clip-ons. From what I see TL clipons bolt to the bottom of upper tripple clamp while GSXR clipons have protruding pin locating clipons to upper clamp. I like bolting design better but My aftermarket billet upper clamp is hollowed to accept a pin. I couldn't just drill and tap upper clamp for a bolt.
Solution: tap TL clipons itself with 8mmx1.25 and use stainless 8mm bolt. I reduced diameter of the bolt in the protruding area to mimic GSXR pin size.
Working GSXR forks:
Building special tools.
My vise has piping clamp so I luckied on figuring out how to hold fork tubes. Spring Compression tool I made from 1 1/4 cast iron pipe union. I got whole union from Lowes for 14 bucks. Piece you want is an union nut. Next drilled and tapped the union nut to match available bolts. Funky bolts I selected are Toyota exhaust bolts. Those are just perfect for the application and make tool better than Suzuki OEM tool I intended to reverse engineer.
Pic here: http://www.sv-portal.com/forums/album.php?albumid=1274
Oil level tool: I see people waste time building elaborate adjustable setups. I come out with just a syringe and plastic straw cut to length, 124 mm in case of my K7 Gsxr1000 Kayabas. Worked perfect.
Pics here: http://www.sv-portal.com/forums/album.php?albumid=1274&pictureid=12410
Working lower triple clamp.
Cleaned out with steel wool. Chased threads and bolts. Waiting for bearing set. Suzuki make head bearing set that includes two bearings and dust seals, whole kit for bout 70 bucks delivered. Better deal than buying items separately. Waiting for delivery.
Lower bearing race looks pita to remove. Not sure if my home compressor will run my I&R air chisel, if so job will be quick....
Got the bearing kit. Air chisel made a snap removing bearing race.
For installation I ground inner diameter of old race with sanding drum. Once hole opened up it went on the shaft without resistance. This old race become drivers head.
Selected evotech because I wanted to retain tag light and oem turn signals. Evotech piece is kind of pricy at 100 bucks.
Just finished installation, not impressed at all. Oem turn signal Reinforcement bar didn't fit, self tapping hardware was not there for the upper plate. Instruction were sketchy. Mounting hardware for an merican tag are joke. There was no hooks to retain relay block. In short shyte.
Looks good though.:evil6:
I supposed to get last parts yesterday but I didn't. Boomer. Went fishing, cut nothing. Boomer. Better day today hopefully, test drove around nignborhood for a first time with new front end. Still faring is off and ignition switch not connected but bike runs fine on new forks.
Last parts are two cooling hoses that connect to thermostat housing and cylinders. I will dig to them and replace fuel filter with new one plus relocate ignition switch to left side. All one job I won't start unless I have all parts on hand.
I spent lots of time trying to place ignition switch and retain its full functionality. Finally I have workable design, just bit fabrication left to do.
First impressions: bike is quicker to turn, yet stable. USD Kayabas make better job over rough surfaces. TLS bars feel like SV stockers.
With tank removed and all work associated with swap I took opportunity to replace fuel filter with new one. That is 3 rd filter I have changed since I cleaned the tank. All to the tune of 24 dollars delivered. Try to price that for factory junk design.
To have more room I am removing filter bracket attached to the filter, just keeping filter body http://www.sv-portal.com/forums/album.php?albumid=1298&pictureid=12610
While at it I noticed connection to the fuel hose connector at the TB end developed a leak. IIRC manual suggests replacing fuel hose after 5 years in service, mine was overdue. Note that date of manufacturing is stamped into connector bodied.
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