79 GS1000 Cafe Racer Build

[ugobug]

HI all, so I am actually like more than half way into my build already...I've just been going at it hard and haven't had time to sit down and write about it.

What I've got going is a custom build. I am taking my 79 GS1000L and updating it, and building a custom cafe racer/streetfighter. I managed to score this bike a little over a year ago, traded it for an old Baja I was parting with. Rode it for the year whilst I contemplated where I wanted to go with it, and then settled on an idea.

I then picked up a 91 GSXR complete bike for parts, and that kind of set the mood for the build. Now, things are way in motion, and I'm getting really excited about the direction it's headed. Here is my build thread. I have a lot of content to upload, as I have been taking pictures as I go, so I will try and get it in order. I've also been tracking my budget penny-for-penny because I'm ballin' budget-style! LOL

The plan is, front clip from the Gixxer with the USD forks on the GS frame, upgrade to monoshock with gixxer swinger, modify the tank, cafe-style seat, minimalist, rear-set pegs from gixxer, Gixxer wheels/tires, plus buddy pegs for the lady to ride with (she likes to ride, not drive)...I also want to build a custom removable seat cowl so I can maintain that cafe look when I'm alone, which is most of the time. Also, getting rid of all the shiny-going all black and dull aluminum, other than a retro 70's style gold leaf pinstripe that scallops the tank and goes down the side of the bike. and of course updated brakes, exhaust, intake, wiring, gauges, switches, etc.

So, here we go!

 

[ugobug]

OK, so here is what I am starting with, a pretty clean GS1000L

 

[ugobug]

Here's the Donor bike. pretty clean 91 Gixxer. was laid over. picked it up for $400. Still ran. good deal.

 

[Rijko]

Nice L to start with, subscribed - interested to see what the blend will look like !

I like original, but also the mix of old and new, working on a GS1000.
I went with 18" PVM wheels, but like the wider tires choice and looks yours will have.
Keep them pics coming

 

[ugobug]

Here's the teardown process.



new front end test-fitted:


cutting and modifying the frame, starting to:


stage 1 weight reduction. LOL. had to make room for the new rear swinger. MUCH wider:

 

[ugobug]

so you can't really tell from the perspective of this picture, but the new rear swinger is approx 3mm wider in the pivot area than the stock steel unit. I decided to grind down the frame the necessary space I needed, as I had a lot of material there and I plan on adding material to the outside to maintain the pivot bolt length and strength, especially with the added stress of the Monoshock on the frame there.


I ended up measuring the bearing diameter, and the pivot bearings were the same outside diameter. So, I ordered new stock Pivot bearings and used the stock inner spacer, as the inside diameter of the pivot bolt on the Gixxer is MUCH larger, and would compromise the strength of the frame if I tried to drill the frame out larger. Pressed the GS bearings right in to the Aluminum swinger and presto! perfect.

First Mock-up fit and measure:




I was also mocking up the fit for the pegs and controls as well

 

[ugobug]

Fabbing and welding. Built a new shock mount, and decided to use DOM tube to build my cross-brace. there will be more gussets and bracing involved...this is just mock-up and final measuring. All this has to be perfect. I must have assembled and tore apart the rear end at least a dozen times already haha. There's a LOT riding on this (literally AND figureatively) haha.

 

[ugobug]

I was trying to come up with ideas as to how I want to lay out my dash, and finally settled on a layout I'm happy with. Since the column lock is worthless now, I decided to cut off the Key (to be located on the side by the electrics later)


and using some cardboard, I mocked up my new Koso Gauge, USB/voltmeter, and RAM mount ball...also drew in where there will be LEDs for the Gear indicators. Engine has it, might as well use it!


and now, starting to strip apart and re-lay out the wiring harness, with some new updated goodies.

 

[ugobug]

Right now I am working on laying out the new harness and tying in the newer controls. I also decided today after doing some research to ditch the stock rectifier and regulator and get a newer style combined R/R. Thanks to these awesome forums!

So that's all caught up for now. I'm also working on organizing my garage as I go, so progress will be slowing down at the moment. To BE Continued...

 

[nvr2old]

A VERY ambitious project. Looks good so far. Lots of trial and error, I'm sure. I'll be anxiously awaiting updates.

 

[steve murdoch]

You don't waste time.
Great progress so far.
btw, $400.00 for the Gixxer was a great not good deal.

 

[ugobug]

Hey there GS world. Got some new updates on my bike build! I've been busy relocating and moving and getting settled, so the GS was in storage for a bit, but now I'm back at it hardcore. Probably won't do the finish work (paint and whatnot) until this winter, so the goal right now is to get it rideable so I can work out any issues that may arise with the build.

For starters, I got the frame work all done and, even though its not very pretty right now, its strong and solid. I will need to get a picture of the finished layout.

also got a wiring box cut, folded and fitted:

wiring components still in layout phase...

 

[ugobug]

Got the Engine Harness cleaned up, refreshed, and re-wrapped. Fed into the new wiring box

Nice and Tidy:

 

[Buffalo Bill]

I'd rather restore the $400. 91 GSXR 1100. Bummed you stripped it.

 

[LightsOut]

Very cool project! Following along. I love oiler gixxers (and ride one) as well but don't mind one being used for a cool build.
I'd take the 1100 (if it was one?) engine off of you for a 7/11 build if it'd been on the same side of the atlantic

Looking forward to seeing the frame work and monoshock mount in more detail.

What are the goodies you added to the wiring harness?

 

[ugobug]

the Gixxer was wrecked. had a bent frame and a hole in the engine case from road rash. Pretty much the suspension and a few other goodies were all that was left good

 

[ugobug]

Finally back on the GS project hardcore after a long hiatus. Will be uploading pictures here pretty quick. Getting close. Hoping to be riding this Spring!