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K6 gsx-r 1000
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Discussion Starter #1
So I found this site hoping to get some pointers and good advice about rebuilding my k6 gsxr 1000. I've honestly never worked on a bike before but I am very mechanically inclined and always believed if someone else can do it the so can I... You know fixing things wise. Anyway I traded a $1000 trailer for this bike, clean rebuild title. Dude Said it had 30,000 miles on it and needed a valve adjustment and new plastics. Once I drove the 5 hrs to pick it up I was informed it didn't have any back brakes and he lost the key. Oh and he thought it needed a new starter clutch. So after poking around the bike and removing what plastics where left I figured out that the starter clutch is fine but the splines on the starter where obviously stripped out so that's one easy fix. Its got a full Yoshi exhaust and a power camander 5.Also the breather is out and wires are everywhere but I'm slowly figuring it out. All the valve cover bolts where in a box except the last one in the far right hand corner thats wallerd out but I can get her out lol. One thing that concerns me is I can see red rtv silicone along the bottom case so I'm pretty sure someone has been in them guts haha. Sooo.... My plans are to get the owners manual on the way. Then replace the ignition lock set, replace the starter, check the stator, rectifier, replace the battery and go ahead and do the valve adjustment myself. Also while I'm in there replace the timing chain tentioner with an oem one and just double check my timing. Of and re wire the radiator fan. If I can get her to fire off I'll sink my carbs and fingers crossed she sounds right then I'll start replacing plastics, brakes, tires chain sprockets and all the other things I can think of. But I'm sure I'll have a bunch of questions and was hoping yall could lead me in the right direction along the way. Thank y'all very much.
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You should listen to me. No, seriously, listen to
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That poor bike. An owner's manual will help but what you really need is the Suzuki service manual. It's available for download. I'm not 100% sure but it looks like you have the frame recall but not the MC recall. Beware, the bracket that supports the MC reservoir was replaced during the recall and has been removed from the market. It has some value for use with an aftermarket MC (Brembo, etc.) so I suggest that you replace it with a junk strap before letting Suzuki do the recall or it will be forever gone. All you need is a key if the ignition lock is OK. That's readily available from a locksmith or, with some finagling, from Suzuki (they have records of the key codes for every VIN and can even make a cut key - expensive). Beware, the ignition, gas tank, and rear compartment locks/keys are interconnected. Wiring is scary. Ebay harnesses are almost always significantly flawed. I'd get the PC-V out of there for now. I think I see a rear brake caliper so is it frozen? It may be possible to rebuild it. Red RTV along the oil pan is OK but not where the three case sections are joined. Suzuki now sells a pan gasket (didn't originally have one). Stripped splines means a new starter but I wonder why that happened, i.e. what else is wrong. An OEM tensioner is probably best. Not good that the breather is gone but it's easily replaced. A properly functioning fan is important. Check the steering head bearings and compression. In addition to several types of standard wrenches you'll probably need some special tools. This will take some time and effort if you're new to bikes.

P.S.
Does "clean rebuild title" mean that it's been written off by an insurance company after a wreck?

The screw into the frame brace that mounts the top of the radiator is easy to cross thread. You need the recall instructions to see how it goes together.

Is the tank rusty? A new main fuel filter is very expensive.
 

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Discussion Starter #3
Oh boy, I'm not sure about the title it said reconstructed vehicle on it. And yes the rtv is around the oil pan. By removing the pcv are you talking about the power camander? Also it looks like he just broke the lever off of the back break and it's missing the bleader plug so I'm sure that can be rebuilt. And Im planning on going with r6 brembo mc in the front . The air breather is here. It was just off. And yes I meant the service manual but I'm definitely having trouble finding one online for the k5 and k6. And honestly I'm not sure about the inside of the tank yet. It's still locked haha. But thank you for the info on a locksmith I know an oem lock set and ignition is like $340. Luckily I've got a bunch of tools and whatever I don't have I'll definitely try to get. Thank you for your input. I know I've got a bunch of work ahead of me and alot to learn along the way.
 

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Wow, what a mess! Who treats a bike like that, like that?

I love it.


Good luck on your new venture.
Are you at all aware of the history/performance of the K5/6 1000?
 

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Locksmiths have things like this that quickly read the lock. Too quickly IMO. Find someone with it or an equivalent.

See here for owner's & service manuals, color wiring diagrams, etc. I regularly update one version of the service manual.

Once you get into the tank, do a fuel flow test as described in the manual. There are endless posts here about issues associated with clogged filters. You want to know that yours is OK.

Yes I'm talking about the Power Commander. It's just going to confuse things if you have wiring issues.

"broke the lever off of the back break and it's missing the bleader plug"
That reeks of crash damage.

The RTV means that the oil pan has been off. Perhaps the drain plug stripped (not uncommon).

From what I see of the exhaust, it looks more like OEM headers. Maybe it's a slip-on. The OEM header bolts can get very stiff in the heads. Now's probably the time to make sure that they come out. Don't break one.

There are Brembos and Brembos. The R6 might be OK, maybe even an improvement over OEM. But it needs to be carefully considered. The recall will get you a new MC and lines. But understand that the OEM brakes aren't very good.

You're going to need a multimeter, ideally a good one.

Per what? above, I hope you understand that this is not an entry level bike.
 

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If you traded a 1000 trailer for this, I hope that trailer was in similar shape
By the time you're done, I wouldn't be surprised the total cost to rebuild it would have bought you in the ballpark of a good one with equal mileage
 

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I'm going to be perfectly honest, it would make more sense to part that out and put the money toward a new bike. You're going to spend a lot less
 

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Discussion Starter #8 (Edited)
Haha y'all are breaking my heart. But really. I know it looks like alot and I'm sure it's more then I can comprehend at the moment but I'm sure I'll be able to figure it out and I love fixing things. Thank you so much for that manual BillV. I really do appreciate all your pointers I'll make sure I check everything you recommend. And yes, I'm positive the guy I got this bike from was thrown off and probably crashed it but at low speeds, there are some skuffs on the covers and bother foot levers are bent in and the plastics where literally held on by zip ties I'm guessing for the catfish pictures lol. Either way it's mine now. He seemed very scared of it, and speaking of that I'm very familiar with the reputation this bike has, I can honestly say it's been a dream bike of mine for the last 12 years. I was planning on perchasing a smaller bike in the spring and working my way up but this kinda fell in my lap, I'm sure it's going to be expensive but I look forward to learning the ins and outs of this motercycle.im sure I would of killed myself when I was younger on this bike. But I'm not gonna lie I'm nervousness as hell but excited at the same time, lol now that I've got a family and am a lil older and would like the come home every night I know I'll be able to handle it. I live in a super small country town and am only gonna use it to go back and fourth to work. And ya it mite make more sense to just purchase another bike and start fresh but I would really really like to be able to use this bike as a learning tool and figure everything out...... Oh and the trailer was a steel for $1000 hahaha.
 

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Poor, poor, neglected and beaten down bike. You would have to pay me to take that thing. Hmm... if you pay me 1500.00 I will come take it off your hands lol!!!

But what’s done is done. At this point I would part it out and go for that smaller bike you were talking about.

Did you actually see it run???? It looks like its has some squid accessories on it. If you actually fix this thing, and the Forks and frame are straight, wheels are straight, rides okay, i would take off those ebay levers and rotors and get something oem.

We won’t keep beating you up over it. Just some advice coming from guys who have been there. I did the same thing to a free kz550 and restored it costing me way more than the bike was worth. (Even with super low mileage) Also I spent enough time on it I could have got a job at WalMart and just bought a brand new bike instead. Then I kept it in my garage for 5 years before I let it go for book value.

If you go ahead with fixing it (sounds like you are) you will find good help here if you listen to people. So good luck.
 

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Discussion Starter #10
Thank you very much sir. and yes, it's got some crap on it and it's lowered. So I'm planning on bringing everything back to stock for the most part.
 

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What is that Tank paint?
And what's with those red wheels?

If that trailer was worth anything, he got the way better deal.

Not trying to bust your balls though. Get it cleaned up, maybe it runs fine? I'm not so sure I'd be making it back to OEM vintage shape, but to get it running and riding OK might be good, if it' runs OK.

If the motor needs a rebuild also- I'd start thinking differently.
check the motor first.- If it's crap- don't even bother with the rest of it.

YMMV
 

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Is that a hole in the left top of the radiator? I see something like an overflow hose running down the left side between the two radiator hoses that I don't recognize. The generator cover has some serious scuffs from crashing and will likely need to be replaced. Because of the reconstructed title you probably ought to use aftermarket plastics. See Le Skid and Auctmarts. It's strange that the chrome "S" badge on the tank was painted over. I'm unimpressed with lowering the bike but that ought to be fairly easy to undo.

P.S. You could remove the ignition switch and take it to a locksmith. But you'll need a T40 security head torx bit and a bit of muscle as a high strength thread lock is used.
 

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Discussion Starter #14
Ya I'm definitely planning on trying to get her running before replace most anything else. I was just going to to throw a cheap set of fairings on after I get everything running right. And that's a great idea about the ignition. I already have a set of security torqs bits. I can definitely remove it and try to bring it to a lock smith.

Lol and the picts of the bike in the add made this bike look 1000 times better then it did in person. And I really don't know what's up with the rims, they are powder coated neon orange, at least they ain't spray painted thought haha. And I'll inspect that radiator. I know I already have to take everything apart with the cooling system because I need to rewire the cooling fan back a mountain bolt out that looks like it sheared off in an acident. If I can't back it out i can weld a nut on the end and get it out that way. I was also planning on replacing the stator and rectifier and stater cover. I'm not gonna lie I was thinking about getting the cheap Chinese ones just to see if I can get it running. Lol the current rectifier is hardwired in by the rear shock with clear blue speaker wire lol.
 

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Discussion Starter #15
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This was the pics from the add. They must of been pics from when the guy first got it.
 

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Discussion Starter #16
Woop Woop local locksmith is out of town till end of next week but quoted me $75. Hell yea.
 

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Please throw that side mount license plate holder in the trash.

I was thinking $30 for the key but what do I know? I think that one made by Suzuki is around $50. A dealer or Suzuki customer service should know.

In looking at your pic of the top of the radiator again, I think I see wire ties holding it in place and the mounting screw through the frame boss and into the frame brace may be broken off. Hard to tell and I previously mentioned that it can cross thread.

The fan is readily available on ebay. It mounts to blind threaded inserts in the right side tank . Some heat may help in removing a broken bolt.
 

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Discussion Starter #18
So I removed the power camander and gas tank, man.... The wires are bad looks like the big black wire was spliced and another wire came out of the bike side of the connector. But at least I found it right haha
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Oh and on a positive note there isn't any rust in the tank.
 

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That looks like the fuel pump connector. Cutting the B/W lead is strange as it runs to a nearby stud with nut at the pump. He could have easily tied in there.
 

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Discussion Starter #20
Oh so here are some pictures of the starter and the gear that goes directly against it. Do y'all think it needs to be replaced? It looks like the outer edge has a little wear on it from the starter stripping out.
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Also can anyone tell me what these 2 plugs are. I found them wrapped in electrical tape besides the battery kinda tucked away. Looks like they are coming out of the main harness
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I removed my ignition witch unlocked my steering column, it kinda sounds squeky like rubber rubbing against metal. Almost sounds like my steering damper is dry.

Got the wrong size eise out for the back right valve cover bolt so that's gonna have too wait a bit also. Kinda a pain to get to lol, just makes it more fun right.
 
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