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A month went by before i managed to get to the shop again.
main thing we did was to fix an ugly dent in the frame
also worked on the upper shock mount (finalizing the shape)
Drilled and welded bolts to the seat base
next time i hope to finish fabrication and take it home for dry assembly before blasting and powder coating.
in the meantime parts continue to arrive at my home from around the globe, still need to decide on things like exhaust, headlight etc
Almost another month, time for another update.
I drew a template for the tray i want under the seat and had it laser cut
Then we bent it on the vise
it required some tweaking to fit but i like how it came out, all the electrics will be hidden inside under the seat.
I still need to grind the welds but i can do that myself (my welder charges by the hour ;-))
That concluded the welding part, the frame is back home and it's time to get it and all the other parts ready for blasting and powder coat.
Some updates are due,
The frame,wheels,lower fork and other parts were sent to balsting powder coating
the front forks were rebuilt with new bushings. oil seals and progressive suspension springs (just waiting for new drain bolts to fill them up and close them)
Swingarm bearings in place, swing arm mounted with new dust caps and custom made spacers to replace the big ugly thing
Seering head bearing races removed, the upper was easy.the lower was hell.
Since my last post i'm still missing some parts needed for assembly (my order was split and the other half didn't arrive yet)
but i did got few things done
New tires
Installed all new bearings, got the rear drum honed and new lining for the shoes
Installed the shocks and did another mock up with the tank and seat pan
Last thing done was rebuilding the brake master cylinder
I do like those mag wheels - wish they made them differently though. And for what it's worth, a GS500 master cylinder is a pretty quick / easy upgrade, and some of them have adjustable brake levers.
Finally, after many months and fairly slow progress the bike is back on two wheels.
I filled the forks,tightenend all the bolts and installed the front wheel (had a small issue with the dust seal, but it's all good now)
Started locating things on the bar, just to see how it looks and what works best,i got another handlebar - wider and lower and i'm conflicting which one to use.
The issue of electrics is a big concern for me, not so much from lack of knowledge but more from the desire to simplify the system, make it reliable and keep it "Neat and concealed"
so i'm trying to plan how to mount the components in the limited space i have under the seat pan.
Are you planning on mounting the reg/rec unit inside of the pan? You may want to be concerned about not getting any airflow across it. Just my .02. Others may chime in with more expertise. Looking good.
I'm still debating whether to mount it under the "box" out in the air. this way i will also have me more room inside.
I just took out the loom from the box it was in since i took it off the bike. it look like a daunting task to try and make it more compact and neat. ant tips would be warmly accepted.
I built the box for my electronics under my seat as well. Its a bit smaller but I made holes for air flow and drainage and mounted the reg/rec on the exterior of the box. I think its like page 5 on my build thread that hasn't been updated in ages. Heres a pic though.
Moving on to the engine, it started and ran at idle before i got the bike,so i know it's more or less ok. but still i want to take a look inside,de-carbon the head and pistons,put some fresh gaskets and generally make sure everything is in place.
My main concern is the timing, there are deep scores on all of the black tensioners and even inside the head cover.
Do i need to split the cases for changing the the timing chain?
Head looks ok i think, dirty but no visible damage.
Cylinders also look good, no gauges or scratches
Pistons are dirty but not heavily, the piston has 0.5 on the top,i guess it was oversized at some point.
I haven't messed with the timing chain on any of my Suzuki's, but I did replace the one on my Honda CL175. On that bike therreplacement chain had a rivet type master link (just like the drive chain). So I didn't need to split the case for that.
Are you certain it is the timing chain that needs replaced and not the cam chain tensioner? There should be a spec in the service manual to measure any "stretch" to the chain.
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