Stu's GS450/500 Cafe/Fighter - Suzuki SV650 Forum: SV650, SV1000, Gladius Forums

Go Back   Suzuki SV650 Forum: SV650, SV1000, Gladius Forums > Workshop > The Build Board
New User? Register - Forgot Password
Register Forums FAQ Gallery Members List Calendar Search Today's Posts Mark Forums Read Motorcycle EscrowInsurance Advertise

The Build Board A place to post a journal or log of your SV / Gladius projects and builds. No replies or discussion are allowed.

Reply
 
Thread Tools Display Modes
Old 08-11-2010, 03:25 PM   #1
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Stu's GS450/500 Cafe/Fighter

This is the start of my project. I bought it as a complete basket case. It was a bare frame and a bunch of boxes of parts.
But the price was right and it has a clean title.

The plan is to put an SRAD frontend and an SV650 swingarm on it with the requisit wheels. And I will be putting a GS500 motor and full wiring harness in it.

I made the seat and I'll be making my own exhaust as well as several other parts.







7Zark7 is offline   Reply With Quote
Sponsored Links
Advertisement
 
Old 08-19-2010, 02:25 PM   #2
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

Well, it turns out I can't use a GS500 motor in this frame without running into some problems with the exhaust headers. They come out straight from the head on a GS500 which puts them right into the downtubes.

That's ok because I've got engines a plenty (long story)
I've got two good GS500 motors, one GS500 motor with rod knock and one good GS450 motor.
So the plan is to pull the bad GS500 motor and the GS450 motor apart and make a frankenstein motor. GS450 bottom end, GS500 barrels and a GS450 head. New rings and gaskets and I should be good to go.
I wonder how hard it would be to retrofit a GS400 kickstarter :-)

I should have more pictures to post up this weekend.
7Zark7 is offline   Reply With Quote
Old 10-01-2010, 08:13 PM   #3
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

I got some more done on the 450 and I also have some engine parts on order. I guess 500 just wasn't going to be enough so here is the plan for the motor.

GS500 cases and crank
GS500 barrels bored to accept GR650 pistons (77mm instead of the GS500s 74mm)
GR650 head and cams.

This will give me 52x... somethng bigger than 500, at least :-)
A better flowing head and higher lift cams.
Plus I will still have the angled exhaust ports.

HUGE thanks to dgyver on this and the GSTwins board for all of the great info on the motor options.

I'll still be using the stock GS500 carbs until I can afford some flatslides.


As for the rest of the bike, I was able to get the front end and the swingarm mounted.

Frontend is and SRAD with a knurled SV stem pressed in. Bolts right up. I just need to figure out some steering stops.

Swingarm was a little more tricky. I had a full inch taken out of the pivot point (1/2 on each side)
Then I had to have some bushings made to fit the ID of the bearings and the OD of the GS450 pivot bolt. All I have to do now is build some points to mount the monoshock.

I will also need ot take some material off of the sprocket carrier so the sprocket will line up and not hit the frame.

I haven't decided how high I want the rear.






7Zark7 is offline   Reply With Quote
 
Old 11-12-2010, 05:46 PM   #4
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

Slow progress. I've got the rear suspension almost done. It's all tacked together and I have to finish welding it. I keep forgetting to bring my camera to the shop so I don't have any pictures of that.

But I did start making my license plate and tailight bracket. Here's what I've got so far.


I still need to cut the sides a little more to get a better curve on them.
Then I can make the other part of the bracket and weld it all together.



7Zark7 is offline   Reply With Quote
Old 11-14-2010, 04:20 PM   #5
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

Brought my camera to the shop and took some pictures of the rear suspension.







7Zark7 is offline   Reply With Quote
Old 11-18-2010, 10:20 AM   #6
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

Sorry, no new pictures. But I got some material yesterday. Some small, medium and large steel tube. I'll be making my own clip-ons, rearsets and headlight brackets.

Wish me luck.
7Zark7 is offline   Reply With Quote
Old 02-13-2011, 04:45 PM   #7
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

First update in quite a while.
I work on the bikes out of two different garages. Mine and my cousins.
One has no heat, the other has no electricity (for now) So I haven't really been able to do anything with the bike.
It warmed up a bit today so I got my ass out there to make some parts. Well, not parts but a jig to make the clip-ons.

Jig is going to be aluminum. Once my cousin gets electricity I'll be able to weld it together.

Then I can start making my clip-ons. (why am I not just buying a set?)




7Zark7 is offline   Reply With Quote
Old 02-14-2011, 04:54 PM   #8
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

I haven't decided if I'm going to use this frontend or stick with the SRAD. If I stick with the SRAD, I'm going to disassemble them and have the uppers anodized gold or blue (I think) and the lowers anodized black.

Either way, this is the wheel I'm going with. off of a 00+ Sportster.


7Zark7 is offline   Reply With Quote
Old 07-07-2011, 11:09 AM   #9
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

Finally made some more progress on this. I didn't like how the right side shock mount was so i revised it to be more like the other side.








Finished all of the welding. Now I just need to cut off a few more tabs and grind everything smooth and then it can go out for paint or PC.
7Zark7 is offline   Reply With Quote
Old 09-22-2011, 01:02 PM   #10
7Zark7
Senior Member
 
7Zark7's Avatar
 
Join Date: Aug 2002
Location: Center Neptune
Bikes: 2002 SV650, 1975 CB360T, 1978 CB750
Miles Kms: ??? No Speedo :)
Posts: 811
Re: Stu's GS450/500 Cafe/Fighter

This is the front end I've decided on.






Cut out an electronics tray out of some aluminum and got some Dzus fasteners.



Ready to be welded.



Will sit flush with the rear bar once it's complete. I'll paint it with some bedliner or something.

7Zark7 is offline   Reply With Quote
Sponsored Links
Advertisement
 
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
##### Café fighter ##### GHOST RIDER Motorcycle Talk 60 12-19-2011 09:42 AM
GS450 Cafe Racer/Streetfighter discussion thread 7Zark7 Motorcycle Talk 27 09-28-2011 11:21 AM
Project SV650 Cafe Fighter complete! c_morse Motorcycle Talk 19 09-09-2011 10:26 AM
Stu's new wheel :) 7Zark7 SV Modifications and General Maintenance 6 02-16-2009 08:04 AM
'82 Suzuki GS450 T Problem rocklax Motorcycle Talk 8 04-13-2007 01:17 PM


All times are GMT -5. The time now is 06:55 PM.


Design Developed by CompleteGFX
Powered by vBulletin® Version 3.8.8
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.
©1999-2009 SVRIDER.com.
Motorcycle News, Videos and Reviews
Honda Grom Forum strong>Kawasaki Z125 Forum Harley Davidson Forum Honda 600RR Forum Kawasaki Forum Yamaha R6 Forum Yamaha FZ-09 Forum
1199 Panigale Forum Honda Africa Twin Forum Roadglide Forum Honda CBR1000 Forum Vulcan Forum Yamaha R1 Forum Yamaha R3 Forum
Ducati Monster Forum Harley Forums Honda CBR250R Forum ZX10R Forum Star Raider Forum Yamaha Viking Forum
Suzuki GSXR Forum V-Rod Forums Honda Shadow Forum Kawasaki Motorcycle Forum Star Warrior Forum KTM Duke 390 Forum
SV650 Forum BMW S1000RR Forum Honda Fury Forum Kawasaki Versys Forum Drag Racing Forum Ducati 899 Panigale Forum Ducati 959 Panigale Forum
Suzuki V-Strom BMW K1600 Triumph Forum Victory Forums Sportbikes BMW NineT Forum
Volusia Forum BMW F800 Forum Triumph 675 Forum MV Agusta Forum HD Street Forum
Yamaha Motorcycles Honda Vultus Forum HD LiveWire Forum Ninja H2 Forum
BMW Scrambler Forum Ducati Scrambler Forum
 

Garage Plus vBulletin Plugins by Drive Thru Online, Inc.