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Project GSXR Part 3
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Friday, 03 October 2014 23:00

After making the decision to keep the GSXR and make a few modifications the time finally came to fit them.  All the web searching was done, items purchased and delivered, time for action.

The fitting of the kit was delayed a few months as I had an injury to contend with, but once up and running again it was time to fit all the shiny new parts. The kit from CMC was complemented with a new double bubble screen from M&P along with a new clutch cable, the old one being the original 14yr old cable. The screen was bought for two reasons, the first was an attempt to alter the airflow to stop some helmet buffeting and the second was due to the fact it would need altering and I wanted to keep the original Suzuki item unmodified.

 

Fitting this type of accessory seems on the face of it to be straightforward, however reality is often different to the plan. Measure twice and cut once, the voice of my secondary school woodwork teacher reminding me to trial fit everything and not to make any major changes until happy with the results. With this in mind the Suzuki clip-ons and top yoke were removed along with all of the switchgear.

 

Fitting up the new yoke with bars attached to the standard risers and extra blocks it became apparent that with them in place it would be impossible to raise the tank for maintenance work making a standard service a chore, not ideal. The extra blocks were then removed and some trial fitting took place, yes the screen would have to be altered but if I was careful with positioning of switchgear and levers, it may be possible to miss the fairing with everything also allowing straightforward maintenance tasks without removal of the top yoke.

The kit was supplied with all of the nuts and bolts to complete the task however some were found to be a little on the short side and some were a bit long. At this point I had decided to replace them all with stainless items anyway, the supplied banjo bolt for the HEL lines was another matter as the one supplied had completely the wrong thread for the standard Suzuki master cylinder. Not an insurmountable problem as I reused the bolt from the Goodridge kit currently fitted and just replaced the washers.

As it all came together a second issue was spotted, the original brake fluid reservoir was mounted directly to the original clip on, a bracket would have to be fabricated. This was achieved temporarily with a piece of stainless wire which appears to do the job quite well although the angle is a bit off due to a slightly short hose.

The M&P double bubble screen was eventually mocked up to check for clearance, which we knew would be an issue.  As it haappened with a bit of measuring, an old rattle can lid as a template, a marker pen and some masking tape the alterations were marked up and ready to cut.  The implement of choice was an old coping saw which worked out really well, much better than the electric jigsaw which had been my first thought.  After cutting, a small amount of refining with some round files and sandpaper was all that was needed to create the desired effect.

 

 

 

 

 

 

Brakes bled and tested, nuts and bolts adjusted and some tweaks to the Renthal handlebar position and out we go for a blast, slowly at first then up to normalish speeds and everything seems good. A quick trip back to the workshop for a check over then a proper ride out.

Riding

Raising the bars and pulling them back slightly has lifted some weight from my wrists and onto my backside which helps with the wrist ache and a bit of back ache. The wider bars give much more confidence in the twisty mountain roads as does the more upright riding position and the new double bubble screen has helped more than I imagined with the buffeting. All in all I am more than happy with the conversion, it doesn't seem to duly affect sportiness of the bike and greatly improves my experience of riding it which is what matters.

Before and after shots show the difference on body position.

The touring duties that were originally envisioned have now been taken over at least in part by a New Acquisition which has lessened the need for further mods but you never know.

New Acquisition –BMW F650 Funduro
New Acquisition –BMW F650 Funduro

 

Project GSXR Part 1

Project GSXR Part 2

Project GSXR Part 3

Project GSXR Part 4 - ITV

Review of CNC Parts

 

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