1992 GSX-R600 Resucitation

12746 Views 47 Replies 15 Participants Last post by OneWing, Aug 16, 2016

Bufftester

Discussion Starter · Apr 13, 2013

2

Just picked up a '92 GSX-R 600 for $450. Has the original fairings (left side ground from being laid over by PO), a couple boxes of bits and pieces, and a full SharkSkinz race fairing. It's in rough shape, but runs, and for the price couldn't pass it up. Started tear down already, pulling the emissions stuff (Cali model), been lurking here filling my notebook with ideas and notes.

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Bufftester

Discussion Starter · #2 · Apr 13, 2013

3

Tear Down

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anthonyrr

· #3 · Apr 13, 2013

What are your plans for the bike?

Bufftester

Discussion Starter · #4 · Apr 13, 2013

Would like to get it cleaned up and running well first, mostly stock nothing ridiculous. Have always liked the classic look of the older gixxers. Working on repairing the fairings, then they'll get prepped/painted. Looking foward to spending some quality time around the Pacific Northwest this summer on it.

THE SRADIATOR

· #5 · Apr 13, 2013

Was it submerged for any length of time?
A-Oooo-Ga...Dive-dive!

Sabba

· #6 · Apr 13, 2013

You've got your work cut out for you, but people have done alot with much worse...

Lots of valuable info on here, use the Search functions (as I'm sure you've been doing), and don't be afraid to ask when you get stuck...

Welcome... :cheers

Bufftester

Discussion Starter · #7 · Apr 25, 2013

5

I've gotten the bike tore down to the frame, starting to clean everything up, fix the numerous broken off bolts/screws, repair wiring and fairings...this thing was filthy. Also working on sourcing an new set of headers, been searching the forums on possible mods from other years, but there is very little info available on exhaust port spacing between model years. In the meantime the sandblasting cabinet is getting a workout.

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Bufftester

Discussion Starter · #8 · May 17, 2013

4

And the assembly begins. New 07 1000 shock for the rear, new wheel bearings in the rear (and front) along with 520 conversion, new swingarm and linkage bearings and steering bearings. Forks apart atm waiting on new seals and fresh oil.

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Sabba

· #9 · May 17, 2013

That shock is a good choice...feels good to get rid of the stock reservoir, it really cleans things up.

Will you be running an airbox or pods?

Bufftester

Discussion Starter · #10 · May 17, 2013

Probably stick with the stock airbox and a K&N element. Everything I have read suggests that there is no gain with pods on the 600. Plan on using Factory Pro kit for carbs (thanks CCMHunt!) and even they suggest stock airbox. Did score another set of stock headers with a V&H slip-on. Also just received a set of race tech .95kg springs for the forks.

Bufftester

Discussion Starter · #11 · May 31, 2013

4

Slow progress, but still forward momentum. CCMHunt hooked me up with a Factory Pro Stage 1 kit for the 600, Carb rebuild is nearly completed. Forks have been rebuilt and reinstalled. Front/Rear brake calipers rebuilt and reinstalled with fresh fluid/pads, They'll get steel braided lines later. Still need to pull the wheels and take them in for balancing with the new Pilot Powers on. Gauges and clipons with new dampers/bar ends and grips. PO really mucked up fasteners and small bits, so a lot of time is going into just getting the right nuts and bolts where they belong. Looking to have the motor back in the frame this weekend or early next week.

My last rebuild project, a KDX220 motor shoehorned into a KX125 frame.

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Sabba

· #12 · May 31, 2013

Bufftester said:
They'll get steel braided lines later.

I picked up a set of Goodridge lines from eBay UK a while back...80 bucks, couldn't be happier...

Might want to get a K&L master cylinder rebuild kit while you're at it, they're around $20, mine was nasty...

Bufftester

Discussion Starter · #13 · May 31, 2013

yeah, the master cylinder rebuild is on the list for the end of the season, surprisingly both were in decent condition. Appreciate the advice and comments, making this much easier and more enjoyable than it would have been all on my own.

GarrettSR5

· #14 · May 31, 2013

THE SRADIATOR said:
Was it submerged for any length of time?
A-Oooo-Ga...Dive-dive!

Was thinking the same thing.

Also cleaned up white wheels look so right on double cradles :drool

Bufftester

Discussion Starter · #15 · May 31, 2013

Yeah, originally I had planned on changing the color to something a little easier to keep clean, but now I think they'll just get a fresh powder coat or white next winter. Wasn't submerged, well, not literally, though it did spend a few uncovered seasons in the Pac NW (which is kind of the same thing).
Have most of the cleaning/repairing/restoring done, now time to start working on fairings and getting them repainted.

anthonyrr

· #16 · May 31, 2013

I love the white wheels as well!

Great project

Bufftester

Discussion Starter · #17 · Jun 6, 2013

4

Finished cleaning carbs and installing the Factory Pro Jet kit, and replaced all the phillips head screws on the rack with hex heads (for the rack mounts) and socket caps (for the diaphragm caps and float bowls). PO had been in there before as the pilots were 32.5 and the mains 105. During disassembly on the #4 air mixture screw there was an o-ring (3x1mm I believe) but no brass washer as on the other three carbs. Does anyone have a part# for the washer, or the mixture screw, or an alternate parts source? I can't seem to find anything that small. I ordered a half dozen of each of the 5 orings from oringsusa.com, but need that washer.

Start of carb tear down

Factory Pro kit (Thanks CCMHunt)

Reassembly

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Sabba

· #18 · Jun 6, 2013

For whatever reason, I cannot find the part number for that washer on any fiche... :scratch

If I were you, I would look around the house at anything that uses small screws, like electronic devices, etc. Maybe you'll get lucky... :dunno

Good choice on replacing those bolts with allen heads...it makes it possible to remove the black slide caps to do needle adjustments with the carbs mounted. Doesn't work so well with Phillips...

Bufftester

Discussion Starter · #19 · Jun 7, 2013

Yeah, I already rummaged through all my house, now looking for excuses to have the neighbors invite me in :shifty lol. My daughter suggested hitting up the beading section at a hobby store as they use small bits like that, if I get time this weekend I'll give it a shot. I had planned on changing the float and cap screws all along for ease of maintenance, but also did the rack mounts because every single one of them stripped first try, it's like they make carb screws out of butter. Got excited to get the motor back in the cradle and had my son help, we got the motor jacked in place and the rear bolts in when I realized that the airbox was still sitting on the bench:banghead. Made for a good stopping point for dinner at least. That stupid air box is huge.

ANDRASTA

· #20 · Jun 7, 2013

Bufftester said:
Yeah, I already rummaged through all my house, now looking for excuses to have the neighbors invite me in :shifty lol. My daughter suggested hitting up the beading section at a hobby store as they use small bits like that, if I get time this weekend I'll give it a shot. I had planned on changing the float and cap screws all along for ease of maintenance, but also did the rack mounts because every single one of them stripped first try, it's like they make carb screws out of butter. Got excited to get the motor back in the cradle and had my son help, we got the motor jacked in place and the rear bolts in when I realized that the airbox was still sitting on the bench:banghead. Made for a good stopping point for dinner at least. That stupid air box is huge.

Not sure if this helps but on my oiler I run the Bst36mm carbs. Yours look quite similar.

If you want I can get the measurement for the washer if you like???

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