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If you look into each rubber boot from the carb end you will see that the pod boot has a large lip on the inside to supposed prevent it from sliding onto the carb too far. This lip plugs up the CV air/vacuum sensing port (oval shaped port on the rim of the carb air inlet) which doesn't let the...

Here's the latest pics of this project. I just got it back up on the table to wrap the exhaust, redo the rear fender strut, and replace the clutch springs.

You can get the pods to work on CV carbs if you use the boots from the original air box and the metal part from the pod itself. The rubber boot on the pod just pulls out and then it will slip over the horn part of the original air box boot. I did this on my GS1000GL bobber project and it works...

A few full discharges, below 10.5 volts, can easily kill these batteries. I'd suspect that first. Does this have a pull the clutch in and make sure the kickstand is down procedure? If so I'd suspect switches in one of those locations. Worst case scenario try bump starting it.

How'd this project turn out? What did you end up going with for a tail light and license plate holder? Do you plan on mounting a fork brace or don't these require one?

It looks like you used the original key latch system to hold the seat on; do you have any pics of how you fabbed that up, the seat pan and the frame side? Also, I have this same bike (build thread linked in my sig) and I found a way to run the cheap pods. I took the boots out of the factory...

imho I think you either need to ditch the electronics "tray" and mount the battery down on the swingarm completely exposed in an industrial sort of way while hiding the rest of the wiring bits in the headlight bucket and/or under the tank or build the electronics bucket to the triangular shape...

Thanks Canyoncarver! I had thought about clear coat but wasn't sure they made it in matte finish until I looked it up this morning. Sure enough, Home Depot carries it locally. Sounds like that's just the ticket. Took her for a test ride Saturday and I'm pretty happy overall. There's some...

Progress...All that's left (before the first test ride) is to button up the back portion of the seat. I do need to mount the tail/brake light and tuck a few more wires but otherwise she's ready to roll for what remains of the riding season up here! Anyone have any tips on what to do to protect...

I used a hot glue gun with pretty good success. It takes a fair amount but held together through (re)carving.

She's ALIVE! http://youtu.be/Fdv5rsNnVKw

Thanks for the replies. If I cut it fairly short is the rolled edge even necessary? If it is, is there a DIY hack to re-rolling it or do I need to get one of those cool sheetmetal bead rolling tools? Not that I need another excuse to buy a new tool but if it happens...then again that cash could...

This is on my '81 Suzuki GS1000L chop/bob project. http://www.dotheton.com/forum/index.php?topic=61604.0 I want to cut down the front fender because, well it's just too damn big and ugly. For those of you who've done it; are you cutting the entire factory rolled edge off and then grinding the...

I like where this build is going, nice work so far. What do you plan on doing for a seat? If you go with a custom exhaust are you going to run mufflers of some sort?

Nice work and great transition. You really knocked the ugly off of her! How long (about) from start to finish?

Progress late last night! Matte black 500° enamel on the barrels and just straight matte black enamel for the rest of it. Now it's on to painting up the bolt-on pieces and parts and then reassembly!! Question for everyone; as you may notice the Suzuki emblem on the left side case cover is upside...

Looks great man! Have you rejetted the carbs for the pods and/or lack of mufflers?

First off I'd like to extend a big thank you to this board for all the inspiration! This place really is a wealth of knowledge and advice. I've been riding since I was 7 starting out on a Yamaha 70 trail. Through the years I've owned a Kawi 650c (wish I still did!), a '70 sporty, and a '89...

Have you noticed any power loss or anything from running those mufflers? What did you end up doing to the carbs? I have this exact same bike and I believe they have different carbs entirely than the older models where you could raise the needles up.