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Discussion Starter #1
1992 gsxr 600: Project Liposuction

Just recently picked up a 92 gsxr 600. Its in rough condition but it was only $900. It runs but I need to do some work on it to get it back in to good riding condition. My goal for this build, as you can probably guess from the title is to make it as light as possible without sacrificing necessities for the street. As I remove parts I will weigh them and put them back to the top of the thread. One thing I have noticed is most the things people take off really doesn't add up to much weight, so hopefully the actual weight of the part will help to form decisions on whether the part is justified to be removed. Before all of the comments of "the easiest way to save weight is going to the gym" are posted. I am 5'6" and weigh an incredible 115lb :lol. So I don't think I can loose anymore weight from my body.
20180424_075641 by Michael Seyller, on Flickr

For some background I am 19 and started building my first bike, a 1978 CB550, when I was 15. I built a café racer out of it with a modern front end, and stripped a lot of weight off the bike. Recently I have finished the bike and I got this bike for a new project that is a little more streetable. I haven't decided if I am going to do a front end swap and wheel swap on this bike but for right now I will start cheap (this is what I said on the last build).
Here's some old pictures of the CB550-
20171112_151355 (2) by Michael Seyller, on Flick
20180214_204734 by Michael Seyller, on Flickr

Here is the list of parts and their weights:
Passenger Seat Lock- .48 Lbs.
rear Turn Signals- .934 Lbs.
Rear tubular mounting bracket- 2.08 Lbs.
Shock reservoir clamps- .116 Lbs.
Rear fender liner- 1.192 Lbs.
Left Rearset Bracket- .302 Lbs.
Right Rearset Heal Guard- .206 Lbs.
Right Passenger Foot Peg- 1.114 Lbs.
Left Passenger Foot Peg- .966 Lbs.
Subframe wire hooks- .12 Lbs.
Front Fender Support- 1.17 Lbs.

Heres my weight savings:
Passenger Seat Lock- .48 Lbs.
rear Turn Signals- .934 Lbs.
Rear tubular mounting bracket- 2.08 Lbs.
Shock reservoir clamps- .116 Lbs.
Rear fender liner- 1.192 Lbs.
Left Rearset Bracket- .302 Lbs.
Right Rearset Heal Guard- .206 Lbs.
Subframe helmet hooks- .12 Lbs.
Front Fender Support- .242 Lbs.
Fairing Bolts- .3 Lbs.
Gas Cap- .614 Lbs.

Total Weight I Have Saved- 6.586 Lbs. (this is with passenger pegs and fender bracket still on bike)

Here is the passenger seat lock. If you remove it you can still pop it off with a flat head.
20180502_185415 by Michael Seyller, on Flickr

I have not removed everything that's on the list. The list is just incase anyone wants to know the weight. I am keeping the passenger pegs on, because I don't have a cowl so I have to leave the passenger seat on. I did remove the extra bolts from the passenger pegs (the third bolt). I also just removed material off the front fender support instead of removing it, because I found out that the front fender is an Airtech (which is really light) and I would like to keep some support for it. I will post the final weight I removed but I was interrupted by tornadoes this afternoon.

20180502_194025 by Michael Seyller, on Flickr
20180502_190813 by Michael Seyller, on Flickr
20180502_191325 by Michael Seyller, on Flickr


My future plans are to put an exhaust on the bike, although removing the can like the previous owner did is probably as light as a full Yoshi :lol. I am also going to run a lithium battery, I did have one but it fried on my other bike when the rectifier came unplugged. I am going to run LED signals and probably run Airtech for the body. I am going to do something with the headlight too. It might be the biggest weight savings. Other than that I am just going to replace the usual wear parts and make the bike reliable
 

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Juvenile Thinker
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293 Posts
Losing the passenger pegs/brackets, the stock rear shock, and most of the rear frame supports is only going to net you a few pounds. Losing the headlight/gauge/front fairing mount will save you that much in one fell swoop. Going to a more modern front end/wheel may shave a couple more pounds, but then you're down to ounces at a time. The truth is these were big, heavy bikes when they were born and will be big, heavy bikes that have attempted to diet when they die.
 

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Discussion Starter #3
Yeah I'll be happy if I shed 20lbs with this bike. Right now I'm not really looking to go out of my way to shed weight, but if there's something simple that sheds weight than I'm all for it. On my last bike it was a similar deal, but I wanted to make it as light as possible, and by the end of it I have changed everything but the front half of the frame and the bottom end of the engine.

I finished lightening the front fender bracket. It shed about a 1/4 of a pound.
20180503_172023 by Michael Seyller, on Flickr

Heres the bike now that everythings been removed.
20180503_174210 by Michael Seyller, on Flickr
 

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Awesome! See my thread on my 6/11 build. Same bike!
I think the main issue with these watercooled bikes is just that they're piggies. I could probably drop a ton on them to get them in race trim, but there's not a ton you can remove to keep them streetable. You're going about it the correct way though!
Attached is my KTM RC390 that is at 283 lbs. :)
 

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Discussion Starter #7
Awesome! See my thread on my 6/11 build. Same bike!
I think the main issue with these watercooled bikes is just that they're piggies. I could probably drop a ton on them to get them in race trim, but there's not a ton you can remove to keep them streetable. You're going about it the correct way though!
Attached is my KTM RC390 that is at 283 lbs. :)
I actually looked through your thread before I went and purchased the bike, nice build by the way. It makes me want to do a 6/11, but its probably smarter if I hold off for now . The KTM looks great too! I bet its fun on the track.
 

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Calamari
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306 Posts
Welcome to the diet club! I like the end result of the cb550, nice job. I have always lived by the "less is more" approach when modifying a vehicle. My '95 750 is on a diet. No idea how much weight I've managed to remove but every little bit helps. They are a few more free things you can do. Drill the rear brake lever and foot shift lever, drill and shave (bottom side) front foot pegs. Remove the helmet hooks and bolts, the mesh screen inside the airbox, tool kit, reflectors, handlebar end weights and the plastic air intake tubes that run from the fairing to the top of the engine.
Now you can spend a little money by replacing all the fairing and bodywork bolts, engine cover bolts, chain guard bolts, battery box bolts, coolant tank bolts and steering stem nut with aluminum pieces.
I have done all of these things and a few more to my bike with no issues. My goal is to shed weight at minimal cost. Keep up the nice work!:burnout
 

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Calamari
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306 Posts
A few more ideas; a lithium battery, compact LED turn signals, aluminum 520 chain and sprockets, aluminum (with steel inserts) sprocket nuts, remove airbox/frame covers (non-functioning except visual appeal), aluminum front fender mounting bolts, aluminum rear brake reservoir mounting bolts, aluminum windshield bolts, magnesium valve cover and signal generator cover (available from '94-'95 gsxr 750).


A word of caution; Do Not Use aluminum bolts, nuts, washers on safety related items such as brakes, hand and foot controls etc... You can use titanium but it is pricey.


Keep us posted of your progress with pics and weights. :burnout
 

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Discussion Starter #12
A few more ideas; a lithium battery, compact LED turn signals, aluminum 520 chain and sprockets, aluminum (with steel inserts) sprocket nuts, remove airbox/frame covers (non-functioning except visual appeal), aluminum front fender mounting bolts, aluminum rear brake reservoir mounting bolts, aluminum windshield bolts, magnesium valve cover and signal generator cover (available from '94-'95 gsxr 750).


A word of caution; Do Not Use aluminum bolts, nuts, washers on safety related items such as brakes, hand and foot controls etc... You can use titanium but it is pricey.


Keep us posted of your progress with pics and weights. :burnout
Thanks. I ordered a bunch of parts and just got a complete aluminum bolt kit for all of the plastics in the mail. It was a little slow going at first, but finally figured out where most of them go. I'll post some pictures tomorrow with the weight savings. Can definitely tell a difference just by holding them. And I'll have to look into the magnesium covers and 520 chain conversion, they sound like a good upgrade without affecting anything. Plus the chain will be rotating weight.
 

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Discussion Starter #13
Heres the weight difference with the aluminum fairing kit. I didn't use all of the bolts in the kit, because I didn't see anywhere else they could go. Also Ill get pics of them on the bike once I fix some of the threads that were messed up from the PO.

These are the weight differences.
Clips- gained .0512lbs over factory. they weighed .0064lbs. more each
small bolts- lost .0576 lbs over stock. they weighed .0036lbs. less each
medium bolts- lost .22-.28 lbs over stock. they weighed .011-.014lbs. less each
long bolts- lost .07. they weighed .012 lbs less each.

I still haven't changed out the wind screen bolts and I didn't add up the weight of changing the metal washers for plastic. Overall I needed the bolts anyways since it was missing half of them, so I'm pretty happy loosing a 1/3 of a lb while I'm at it.

Total savings- .3lbs


These are the clips that came in the kit they are actually heavier than the stock clips.
20180510_120534 by Michael Seyller, on Flickr

20180510_120513 by Michael Seyller, on Flickr

Heres the longer bolts. I replaced 6 factory bolts with them.

20180510_120328 by Michael Seyller, on Flickr

20180510_120344 by Michael Seyller, on Flickr

20180510_120313 by Michael Seyller, on Flickr

These are the small bolts. 16 of these were used.

20180510_120259 by Michael Seyller, on Flickr

20180510_120229 by Michael Seyller, on Flickr

These are the Medium Bolts. 20 were used.

20180510_120411 by Michael Seyller, on Flickr

20180510_120359 by Michael Seyller, on Flickr

I also ordered the magnesium covers last night.
 

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Discussion Starter #15
GSXR 600 '91-'92 GSXR600 drag bike, fairing, fairings, tail, seat, front fender, rear hugger, upper, lower, bellypan, fuel tank, undertail

I like the direction that you're taking with this project.
The 750 magnesium covers are a great idea.

I think you could save some weight with a super bike seat, and still keep it streetable.
Thanks, I'm going to switch to airtech for the fairings eventually, but for right now I'm trying not to spend a lot of money all at once. I like the fact that on the supersport seat you can keep your factory seat, though I'm not opposed to having a place like saddleman build me a new one.

Saw this picture on their website with the seat on a bike. Looks better than factory to me.
 

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Discussion Starter #16
I got some more parts in this afternoon. I got a new screw in fuel lid. It's chrome but I liked the style of it better than the others, so ill just have to either repaint it or polish it. It makes it a little harder to shut but its worth it considering the tank was messed up around the fuel lid where someone tried stealing it or lost the key. By the way it only cost around $20

Weight:
Old lid- 1.014 Lbs.
New Lid- .4 Lbs.

Total Savings- .614 Lbs
 

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Discussion Starter #18
Its been a while since I have posted last. Mainly due to moving back home from college for the summer, but I've still been working on the bike.

put some new mirrors on it. Saved some weight on them, about half a pound but I mainly just replaced them because the old ones were broken.
20180517_151532 by Michael Seyller, on Flickr
20180517_151523 by Michael Seyller, on Flickr
20180517_151742 by Michael Seyller, on Flickr

I put a new wind screen on, since I didn't like the purple.
20180615_132106 by Michael Seyller, on Flickr

I also made a new license plate bracket out of aluminum and tapped the frame to bolt it in with some aluminum bolts. I also replaced the taillight with a smoked taillight that has integrated signals.
20180518_120354 by Michael Seyller, on Flickr
20180615_132037 by Michael Seyller, on Flickr

I've also cleaned up the carbs on it and found that one of the brass tubes were broke, I jb welded it for now but ill eventually replace it. I also put a K&N filter on the bike but it made more of a difference than I thought so I have the airbox restricted for now so I can ride it. I'll order a new exhaust and dynojet kit for it in the near future.
20180615_132026 by Michael Seyller, on Flickr
 

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Discussion Starter #20
little update on the bike.

I decided to swap the swingarm for a braced swingarm off a 95. After ordering 3 swingarms through ebay I finally got one that was in good condition (like it was supposed to be), but I guess that's the way it goes on ebay sometimes.

I have started the swap but ran into a few part that I hadn't ordered so ill order them and should wrap up the swap next weekend. I'll also get the weight difference on them once I bring my bike back from my dads house.

I have also added an led tag light to the bike (which I don't have pictures of at the moment). I installed a factory exhaust and put a dynojet stage 1 kit in for the K&N filter, now the bike runs good and I was taking it to work a few times a week. I installed new brakes on the rear because it didn't have any before. I took the wheels to the powder coaters a week ago because I hated the red on them. I chose to have them painted a semi gloss black because I saw a picture of a bike with semi-gloss black wheels with a red stripe and liked the look, but i'll probably go with a white stripe instead. I also got an 07 gsxr 1000 rear shock to swap over and sent the yellow spring that was in the shock to the powder coaters as well.

The bikes been running good and I have just been trying to get it to the point I want it. I almost picked up a donor gsxr 1100 to do a 6-11 swap but I talked myself out of it because im going back to school soon and will probably need the money for books :crying:. I may do it next summer though.

For the meantime I found a full yoshimura 4-2-1 exhaust off a 750 that was in decent shape and for a good price so I just ordered it tonight.


here are some pics of the bike now and ill get more next weekend when I get the rest of the parts in to button up the swingarm/shock swap.

Jjj by Michael Seyller, on Flickr

20180818_115931 by Michael Seyller, on Flickr
 
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