New mods (GS 550 Cafe Racer)

[sven77]

Hey guys,

for those of you who are interested in I?d like to show how I modify my ?79 GS 550 E Cafe Racer during the upcoming weeks.
If you have any questions about, don?t hesitate to ask.
(Please notice: I am not permanently online, so it might last a little bit to my answer, but I?ll definitely answer all questions. So, be patient, please. )

That?s my GS Cafe Racer basis:
IMG_0445.jpg

The planned mods:

• Frontend upgrade
• New designed dashboard
• Engine upgrade (planned for winter 2016/2017)

Greats Sven

[sven77]

Step 1: Frontend upgrade

Part list:

Suzuki GSX-R 1000 K1 fork
Suzuki GSX-R 1000 K1 brake calipers
Suzuki GSX-R 750 SRAD crowns with steering rod an handlebars
Kawasaki GPZ 305 (Belt Drive) steering tube bearings
Kawasaki Z1000 clutch lever with LSL lever (6 times adjustable)
Ducati Hypermotard 1100 radial brake cylinder with LSL lever (6 times adjustable)
IMG_1118.jpg

[sven77]

Fork mounted today:

IMG_1368.jpg

[tkent02]

Looks great! What are your plans for the engine?

[sven77]

Thanks.

I bought a second engine (GS 550). It will be upgraded with GS650 cylinders (custom sleeves for 65mm pistons), dry clutch, fine-balanced crankshaft and Suzuki GSF600-carbs. Hopefully it will have 80+ hp. That?s the plan so far.

Greets Sven

[tkent02]

80+ should be easy. Do you know about the group buy we are doing for 65mm pistons?

[sven77]

Yes, I read it already. But for me it is too early. (Engine upgrade starts not until December 2016.)

[TeamNeal]

That bike looks amazing! Could you possibly give a little detail about the rear end? Like what s/a wheel brake combo you used. The front swap is awesome man. I have a ported and polished 650 head if you are interested...

[tkent02]

I'm interested if he's not...

[sven77]

Thank you.

The swingarm and rear brake caliper is out of a Kawasaki ZR750 Zephyr (?91/?92). Rear wheel is from a Suzuki GSF 600 (4,5 x 17 with 160/60 ZR 17), axle also. The rear shocks are accessory stuff. Hopefully replaced by ?hlins someday.
Tail light is usually built in a Kawasaki ZX9R, the tail cover is a modified GS550E-item.

Greets Sven

I am definitely interested in the head but how does it come to Germany? And what?s the latest price? Maybe you contact me by PM?

[sven77]

Next step will be preferred (new designed dashboard):

That?s my current one:


As you can see I made some mods before that make the adaption of the new one much easier. For examle the central connection plug. With this I can dismount the dashboard completely with only a few little steps.


My plans for the new one:

• New digital speedo with rev meter
• Substitution of the original gear indicator by a LED 9segment version
• Integration of a digital voltmeter
• USB charging socket AND lighter socket
• Integration of a hazard flasher
• New order of instruments
• Dashboard size as small as possible
• Real carbon layer on top for a nicer look

Work starts in a few days.
News and new pics are coming soon.

Greets Sven

[Rensdw]

Please elaborate on the rear-view camera, that's making me curious.

[Buffalo Bill]

I was wondering if those were race legal? Probably not, racers would block passing like crazy, they already do without.
Great graphics, as well as the rest of your work.

[sven77]

Great graphics, as well as the rest of your work.

Thank you.

Please elaborate on the rear-view camera, that's making me curious.

That?s a quiet simple thing. I took a 4.3"-LCD monitor for my dashboard


a simple, small camera and mounted it in the back of my bike.


A little bit of wiring and that?s it.

Greets Sven

[sven77]

Today I started to work on my new dashboard.

My plan is to make it with a multi-layer construction. First I had to cut pvc plates into similar pieces. Then I installed 2 centering pins to make sure that all layers always are in the perfect position.


I drilled holes in predefined places.


After a few further steps this is a preview to the order of instruments:


Greets Sven