Yet Another GS/GSXR Hybrid Project.

[Quasimodo]

Hello everybody. Just testing the water here and making sure whether this is the right forum to post my questions as I transplant the front-end from a 1991 GSXR1100 to my 1983 GS750E. Currently I'm only planning to do the front-end and leave the stock rear.

No pictures at the moment as I haven't started, yet.

So, if this isn't the right place for it, please let me know. If it is, here's my first question: I need some sort of a handlebar riser to allow for a more upright riding position. The stock GSXR clip-ons along with the shorter forks would make me stoop over the tank too much, and it'd force me to either re-route many cables or order custom shorter ones. I know about the LSL Superbike Riser Kits, but they're rather expensive and quite hard to find, at least for this GSXR model. I'm hoping that there's a top clamp from another bike that would fit and, even better, already offer a taller position. Is there such a thing? The diameter of the GSXR fork is 52mm.

Thanks.

 

[salty_monk]

You'll want to at least fit a 4.5" GSXR wheel in the back so you can run radials at both ends. Bike will be unstable with Radial front & Crossply rear.
Plenty of room for the 160 tyre in there. With a custom Brake mount (I can give you a PDF file of this so you can have it made or drill & shape it yourself) to mount an earlier model GS caliper (with the Banjo bolt on the back) & a custom (I have one of these you can buy) torque arm it's a pretty simple process.

You'll probably have to put a spacer behind the front sprocket or use an offset sprocket & also run a 520 setup.

This is the wheel you want: http://www.thegsresources.com/_forum/showthread.php?t=156160 - this is my for sale thread.

This is the kind of thing on the arm. Actual shape is a bit different.

Here's my bike - I used a 5.5" rear wheel but it was LOADS more work to fit.

Can see the brake in this one:

and in the Video.. still "curing" the paint on the pipe in this one!



Mine is a RSU GSXR 1100 front end. Sounds like yours is USD. You can run a Honda CBR top triple to gain a bit of extra height. Drill the top tree plate & fit risers & a standard bar, plenty of people have done that. I got some custom bars bent up with some rise in them to use in the GSXR top triples. The ones in the pics were 4" & were not strong enough so I have switched back to some 2" ones made with 2mm wall thickness steel tube then powdercoated. It's a little more aggressive than stock (about 2" lower but I managed to get them a bit further back).

Good luck with it!

Dan

 

[Quasimodo]

First of all, thank you very much for the detailed reply.

Second of all, I've got a few more questions below based on your response.

You'll want to at least fit a 4.5" GSXR wheel in the back so you can run radials at both ends. Bike will be unstable with Radial front & Crossply rear.

Silly question, how unstable? Unsafely so?

Plenty of room for the 160 tyre in there. With a custom Brake mount (I can give you a PDF file of this so you can have it made or drill & shape it yourself) to mount an earlier model GS caliper (with the Banjo bolt on the back) & a custom (I have one of these you can buy) torque arm it's a pretty simple process.

Just to be clear, do you mean to say the 4.5" wheel will fit into the stock GS750 swing arm? The reason I'm asking is because I've neither fabrication skills nor, at present, facility. At least not that I can find for the latter. So, if something doesn't bolt-on, it'd be a problem.

Yes, please send me the PDF file. It may come handy later on. Thanks.

You'll probably have to put a spacer behind the front sprocket or use an offset sprocket & also run a 520 setup.

I've seen some pictures of offset sprockets around here, where can I order those from?

This is the wheel you want: http://www.thegsresources.com/_forum/showthread.php?t=156160 - this is my for sale thread.

I do have a rear wheel from the same GSXR1100, but I don't know what size it is. If it's not a 4.5", then I may be contacting you about the one you've got.

Here's my bike - I used a 5.5" rear wheel but it was LOADS more work to fit.

Very nice. It'd be easier to just buy yours. You selling?

Just kidding.

Mine is a RSU GSXR 1100 front end. Sounds like yours is USD. You can run a Honda CBR top triple to gain a bit of extra height. Drill the top tree plate & fit risers & a standard bar, plenty of people have done that. I got some custom bars bent up with some rise in them to use in the GSXR top triples. The ones in the pics were 4" & were not strong enough so I have switched back to some 2" ones made with 2mm wall thickness steel tube then powdercoated. It's a little more aggressive than stock (about 2" lower but I managed to get them a bit further back).

Good luck with it!

Dan

Yes, they're USD forks. I'll do a search later, but do you happen to know which year and model CBR would work?

Thanks again.

 

[Guest]

I've got a gsx600f front end on my '83 with a 4.5 rear wheel with a 160/60 Dunlop roadsmart radial with the stock swingarm. (and a Hagon monoshock) If you do the front end you need to do the rear too. You'll love how much better it will corner....

 

[Quasimodo]

I've got a gsx600f front end on my '83 with a 4.5 rear wheel with a 160/60 Dunlop roadsmart radial with the stock swingarm. (and a Hagon monoshock) If you do the front end you need to do the rear too. You'll love how much better it will corner....

All right, you talk me into it.

Some questions on the details:

1. I take it I'll need an offset front sprocket like Dan said. Where can I get one of those? And how much (i.e., measurement) offset?
2. What about the torque arm/bar? Did you make a custom one also? Or, did you do something different for your rear brake?
3. Not related to the rear wheel, what'd you guys do for the clocks/gauge? Use a stock set that matches the front-end or a 3rd party one like Acewell?

Thanks.

 

[salty_monk]

Will answer your questions in turn.

Yes if you don't do the back wheel too it will be unsafely unstable!

Yes the 160 will fit the stock swingarm. You will have a 5.5" wheel like mine but that will NOT fit the stock swingarm without loads of work to gain clearance.

1. Maybe... I have just a 6mm spacer & running a 530-520 conversion sprocket (the one with the lump on the side) with the lump on the inside not the outside as it's meant to be.

2. Torque arm/bar is custom made. I have one of those spare (had 2 made) that you can buy for $30 plus postage.
Wait till you see what brake rotor you get before I send you a PDF as there are a couple different diameters. The one shown in my pic above is the best one for the conversion I did as if you use the smaller one (as on my bike) you a. lose power & b. have to grind some parts on the caliper to create clearance.
This conversion requires an older GS1000,GS850 caliper that is plentiful & cheap (or with the bigger rotor to me you might just have enough clearance to use the stock 750 one where the banjo bolt fixes on the side of the caliper.

3. I made a custom plate to mount the ignition & clocks but it will be different to yours. I am going to fit an Acewell or http://www.kosonorthamerica.com/ one of these in order to overcome speedo accuracy & space behind the fairing issues next.

It's yours for $6k if you want it

 

[Quasimodo]

Yes the 160 will fit the stock swingarm. You will have a 5.5" wheel like mine but that will NOT fit the stock swingarm without loads of work to gain clearance.

Dan:

Please check your PM about the wheel you've got.

Maybe... I have just a 6mm spacer & running a 530-520 conversion sprocket (the one with the lump on the side) with the lump on the inside not the outside as it's meant to be.

Would you happen to have a picture of this? I'm not sure I've understood this correctly.

It's yours for $6k if you want it

That's about $8K more than I can afford.

I've got a gsx600f front end on my '83 with a 4.5 rear wheel with a 160/60 Dunlop roadsmart radial with the stock swingarm. (and a Hagon monoshock)

KingOfVenus:

Do you also run a 530-520 conversion on your bike?

Just curious.

I'm most probably going to start the conversion work in the summer when it gets a bit hot to ride where I am (AZ), though I may mock up some of it in the next few weeks.

Thanks.

 

[salty_monk]

520 conversion gives you more room between frame & tyre. You may not need it with the 160 though....

I can prob give you the brand & the part number for the sprocket I used!! Chase me up on it as I'll have to do some digging.

Sent you a PM back. I have a new 16 tooth 520 front sprocket but it's a JT not the one I am describing.

Spacers are cheap from Z1 enterprises. You have to grind the sprocket nut down a bit & use threadlock rather than the lock washer but it works ok.

Dan

 

[steve murdoch]

Dan, when you are digging around for the sprocket info could you also check for the spacer #/info. I could not find anything on the Z1 website.

 

[salty_monk]

Used their search function... "sprocket spacer".

http://www.z1enterprises.com/SearchResult.aspx?All=True&KeyWords=sprocket spacer

I used the 6mm one. It's a simple part but the inner dia is a funny size & needs to be exact (out dia is not so important) so hard to find anything local (but easy to make if you have a lathe).

Dan

 

[Quasimodo]

Just thinking through some of the details at a high-level. For instance, brake lines. What would be the best thing to do? I know I'd want stainless steel braided lines, but should I try to source pre-made custom ones or just get the necessary bits from http://www.anplumbing.com/shop/ or so and make them myself?

Also, the handlebar risers. Any idea which year and model CBR top clamp would fit 1991 GSXR1100 52mm forks?

Thanks.

 

[Guest]

Dan:

Please check your PM about the wheel you've got.



Would you happen to have a picture of this? I'm not sure I've understood this correctly.



That's about $8K more than I can afford.



KingOfVenus:

Do you also run a 530-520 conversion on your bike?

Just curious.

I'm most probably going to start the conversion work in the summer when it gets a bit hot to ride where I am (AZ), though I may mock up some of it in the next few weeks.

Thanks.

530 with no offset at all.

 

[salty_monk]

That's the easiest way then... you definitely have room for a 520 setup with no offset on the sprocket if you want to use that 520 sprocket you bought off me with the wheel.

I also have a 16 tooth 520 JT front sprocket that you can have cheap if you want it but with that rear I would probably go with a 17 tooth personally.

Dan

 

[Quasimodo]

That's the easiest way then... you definitely have room for a 520 setup with no offset on the sprocket if you want to use that 520 sprocket you bought off me with the wheel.

I also have a 16 tooth 520 JT front sprocket that you can have cheap if you want it but with that rear I would probably go with a 17 tooth personally.

Dan

That sounds very promising. I'll see if I can mock-fit the rear wheel some time this weekend and post some pictures.

Thanks.

 

[Quasimodo]

530 with no offset at all.

Thanks for the info.

Would you mind sharing some details on your rear wheel set up? Because it sounds like exactly what I want to do. For instance, do you use the stock calliper and torque arm? How about the rear sprocket? Do you have to add/remove any spacers or anything like that to make things align properly? Anything else I should be aware of?

Thanks again.

 

[Guest]

Entire wheel assy from an '89 gsxr 1100, brake rotor, caliper and caliper mount also. Homemade tubular brakestay arm. Stock 750es sprocket side spacer, brake side spacer width cut down slightly, (on a lathe) arm widened alittle with a hydraulic (bottle style) jack and a torch. gsx600f rear axle, had to use gsx600 wheel bearings also. 1100's used larger dia. axle than 600/750's, you could use larger axle if you enlarge the axle slots in the swingarm.

 

[Quasimodo]

Entire wheel assy from an '89 gsxr 1100, brake rotor, caliper and caliper mount also. Homemade tubular brakestay arm. Stock 750es sprocket side spacer, brake side spacer width cut down slightly, (on a lathe) arm widened alittle with a hydraulic (bottle style) jack and a torch. gsx600f rear axle, had to use gsx600 wheel bearings also. 1100's used larger dia. axle than 600/750's, you could use larger axle if you enlarge the axle slots in the swingarm.

Thanks for the detailed info. I'll try to fit the 4.5" wheel this weekend and see how it goes. I'll post pics and I'm sure I'll have more questions.

Thanks again.

 

[Quasimodo]

I took off the stock wheel and try to fit the 4.5" one and here are some pictures:

Needless to say I've some questions:

1. Monk, which year/model Suzuki did the wheel come from? I found that the stock axle is too small for it, so I'll have to get the rest of the rear assembly provided I've a matching parts bike.
2. As the second picture shows, the wheel rubs against the swing arm on the right side. It doesn't seem too bad and I may be able to shift it to the left a bit more; but, if it's necessary, can I grind off a little of that existing weld on the swing arm?
3. Going back to the larger axle, how can I enlarge the existing slots in the swing arm? Kingofvenus, how did you do yours?
4. I'll have to come up with a new torque arm, for sure. Any tips on how I can make one myself?
5. A silly observation, the riding height will be lower with the lower profile radial tyre, yes? Which is fine since I'm a short bastard with an even shorter pair of legs anyhow.

I think that's all for now. Thanks.

 

[salty_monk]

I'll try to answer in turn:

1. I don't know for sure as I bought it off a member here & he didn't know either. I assume late 80's 1100. I wouldn't change the axle I would change the wheel bearing if necessary.

2. You should have plenty of room with the 160. You shouldn't need to mess with the welds. How do you know the wheel is in straight in the pics? You can't determine anything until you really start to bolt it up. You can move it back to create more room at the front where it's touching.

3. The 1150 Swingarm is similar (not identical enough to interchange) & the back end where the axle goes is identical except for the fact that it's the bigger 20mm (I think 20mm is right) axle. You could enlarge the slots to make the slots identical to the 1150 swingarm slots (it's what I had to do), but it's pretty difficult & time consuming to get it right... You could then run 1150 Axle & adjusters. - Again I would probably change wheel bearing first, cheaper & easier. You should be able to get bearing in any auto part store by number or you may find the ones out of your stock wheel will fit if they are in good condition. (Outer dia should be the same).

4. Buy the one I keep offering you... I've done all the work for you on that one. Failing that cut the ends of the stock one & weld something up yourself. You'll need to fabricate a plate with 3 holes in it to the correct dimensions to go with it as your rotor is different size to mine. You also need to determine whether there is clearance for the stock rear caliper otherwise you'll have to use a GS1000/850/750/550 one with the banjo bolt at the rear like me.

5. My bike is lower yes but it's mostly to do with the front end being shorter not the rear wheel. Rolling radius of the wheel is not a lot different from memory.

 

[Colorado85gs550]

Listen to EVERYTHING Dan has to say..........it will ONLY make things better!

Good luck with the project, remember to post LOTS of pictures for all of us gearheads to drool over.....