Suzuki GSX-R Motorcycle Forums Gixxer.com banner

1 - 20 of 65 Posts

·
Registered
Joined
·
105 Posts
Discussion Starter #1 (Edited)
Hello there, some of you may have seen my other thread asking questions about wheels, I figured I'd start a thread for this project since its good to have all my questions in once place rather than different threads that wander all over the place. I've fixed up several bikes over the years but this is my first Suzuki so I'm excited to start on this project.

The history of this bike that was related to me from the seller is this; his father bought this bike new, hopped it up, rode it a ton, and then sold it in the late nineties. Earlier this year he saw a guy driving this bike around and realized it was his dad's old bike so he chased him down and bought the bike off the guy. He didn't have the time or money to fix it up so he passed it on to me. Obviously his dad loved it because there are lots of cool parts on it but whoever owned it after him did a real number on it.

I've been wanting a new daily rider, something cool, but not too nice so that I worry about it. My plan right now is to get it on the road and ride it, not do anything too crazy. I'm going to attempt to do my own "dirtbag challenge" and build this thing for less than $1000 including the purchase price. I think its doable because this project is pretty complete, I have a ton of parts just laying around collecting dust, and I have a friend who used to race these bikes who has a garage full of parts that he will let go for cheap.

First thing to tackle is the wiring; its a total rat nest. The PO already started stripping it out to fix it. I found a PDF of the service manual, and am trying to determine what parts are missing from electrical system. For a second I thought these bikes didn't have a regulator, but after scrutinizing the diagram it appears its in the alternator. Very strange. I'm going to wire it first just to run to see if this turd is worth building, if it cooperates and runs then I'll do a proper harness. Here's some pics of the nightmare wiring job, the V&H Power Pak, which I checked to see that it had the corresponding advancer.
 

Attachments

·
Premium Member
Joined
·
730 Posts
This bike has a lot of potential.I'm looking forward to seeing how it turns out.
 

·
Registered
Joined
·
105 Posts
Discussion Starter #5
I hacked the wiring and it fired up with a squirt of starting fluid. I then pulled the carbs and suspecting they were super dirty, took them apart. Turns out they are RS36 flat slides. Nice upgrade for a hot motor. Also it appears the slide pivot shaft is held on with spring pins. What is the best way to remove these without doing damage? I really want to do a deep clean on these carbs because they are so dirty.
 

Attachments

·
Registered
Joined
·
105 Posts
Discussion Starter #7
Carbs are disassembled, and I soda blasted everything and did an initial clean, focusing on cleaning out the needle bearings and regreasing them. Most of the rubber is rock hard so I will replace the o rings, and a couple other things. The header basically has barb wire holding things together and the back mount was held on with a piece of a door handle. I assume the primaries slip out of the bolt on flanges? Seems pretty stuck, but I want to confirm before I get rough with it. Literally every piece of the plastic including the headlights, seat ,and tail is broken or mangled so I'm chucking it all except for the upper fairing which I will repair. Yes those are wood screws.
 

Attachments

·
Premium Member
Joined
·
650 Posts
Looks like you have a nice project on your hands. With your budget it will take a lot of blood, sweat, and time to get that looking good. Good luck and I’ll be watching your build!
 

·
Premium Member
Joined
·
4 Posts
Your wiring looks like my 85 when I started in on it. I ended up rewiring everything myself with a motogadget m-unit to simplify things a bit and I am thrilled how it turned out.
 

·
Premium Member
Joined
·
257 Posts
I don't post much anymore, but innocuous little statements like this are what keep me coming back to read these threads. I had never heard of this before and it looks pretty darn useful.

Your wiring looks like my 85 when I started in on it. I ended up rewiring everything myself with a motogadget m-unit to simplify things a bit and I am thrilled how it turned out.
 

·
Registered
Joined
·
105 Posts
Discussion Starter #11
Your wiring looks like my 85 when I started in on it. I ended up rewiring everything myself with a motogadget m-unit to simplify things a bit and I am thrilled how it turned out.
The m-unit is a great product, however it would kill my budget.
 

·
Registered
Joined
·
105 Posts
Discussion Starter #12
I got the bike titled so this project can proceed full steam!
I decided to do the fun part first to get me motivated and give direction to the whole thing.
Started sanding the fairing down to bare plastic, there had to be 1/4" of paint on this thing. At this point I realized this fairing has been repaired many times and was cracked everywhere. Coincidentally my dad recently finished building a wooden kayak and had a bunch of resin and fiberglass leftover that he gave to me, so I got creative. I made a crude jig and mounted the original fairing on it then filled in voids with clay. I also did a thin final layer over the whole thing inside and out to seal in the original fairing because I just kept finding new cracks.

I'm going to use a 4.5" Harley headlight with a custom bucket i made years ago and never used. Offset, endurance style; i rounded over the opposite side of the fairing as well to compliment the look.
 

Attachments

·
Registered
Joined
·
105 Posts
Discussion Starter #13
I'm going to try something I have never done before and fabricate and aluminum rear cowl. Needs some bashing and trimming but its getting there. Total cost of the cowl with stick on seat will be about $40 depending on how much I spend on fasteners. I don't want to cut the frame and don't want to do any mods that couldn't be reversed unless the part is fubar.
 

Attachments

·
Registered
Joined
·
105 Posts
Discussion Starter #14 (Edited)
I traded some parts for a bunch of seals and gaskets, 6 pot calipers, a used 530 chain, fork seal driver, and a valve adjustment tool.

I had time to inspect the rear wheel. There was no spacer on the sprocket side except a steering neck lock nut that was doing absolutely nothing as the sprocket bolts were grinding on the swing-arm. I have a 10mm thick 20mm spacer that came in the box of parts that fits in the rear wheel dust seal perfectly. However, when the rear is assembled with that 10mm spacer there is not enough room on the other side for the remaining spacers. Is it possible the PO assembled the rear wheel without this spacer at some point and cranked on the axle hard enough that the swing arm bent and now the spacers won't fit? I got two rear wheels in the deal they appear to be identical, except with different disks. One is missing a bearing and the bearing spacer, and the other needs new bearings completely. The stepped spacer that goes in between the sprocket carrier and wheel is missing completely. Does anyone know what year GSXR these wheels are off? Or better yet, could get me some measurements of the sprocket carrier internal spacer, or a measurement of the swing-arm width? It would greatly appreciated.
 

Attachments

·
Premium Member
Joined
·
4,430 Posts
the rear wheels appear to be from the 90-92 750/1100's, but there should be a 2 digit year mark on one of the spokes. there are differences in rear wheels.

if it is from an oil-cooled, then run stock first gen or 90-92 750/1100 spacers. otherwise, you might have a water-cooled rear wheel, which requires different spacers. verifying the wheel year code is important.
 
1 - 20 of 65 Posts
Top