Brand new shiny Suzuki day

Discussions and updates on your new bike, your new build, your wishes, wants and desires
User avatar
Taipan
Posts: 12692
Joined: Sat Mar 14, 2020 1:48 pm
Location: Essex Riviera!
Has thanked: 14943 times
Been thanked: 9450 times

Re: Brand new shiny Suzuki day

Post by Taipan »

Bike crashes tend to leave me one of two ways and i'm never sure which is worse. First scenario is bike is smashed up/beyond repair and i'm broken a bit but i'll mend. This one leaves me thinking fuck the bike i'm lucky to be here. Second scenario is like yours where you end up with an overwhelming sense of annoyance at your self and the minor damage you've caused that could have easil been avoided. As I said, i'm never sure which is worse tbh? But the overriding conclusion and old adage is any crash you walk away from is good and if the bike is serviceable, even better...
Bustaspoke
Posts: 1593
Joined: Wed Mar 18, 2020 5:55 pm
Has thanked: 2936 times
Been thanked: 1519 times

Re: Brand new shiny Suzuki day

Post by Bustaspoke »

Seeing as it's been pouring down AGAIN this morning I decided to commence with the tope yoke conversion.
I did the same conversion to my Gen 2 bike last year & I knew it would be 'awkward',so far it's proving more of a PITA than it was on the Gen 2 bike.
The main problem is getting access to the ignition switch connector,the cable is the one wrapped with some blue tape on this image just in front of the headstock,I think it goes to a cross tube above the front cylinder head..
Image

The next issue is that when I get the cable disconnected I still have to remove the switch from the top yoke,on the Gen 2 bike the ignition switch mounting bolts are threadlocked,you just heat them up & remove,but on the Gen 3 bike it looks like the switch is secured with some kind of sheer bolt :wtf: ,any ideas on how to remove the ignition switch?

Image
kendo57
Posts: 292
Joined: Sun Apr 05, 2020 6:16 pm
Has thanked: 231 times
Been thanked: 538 times

Re: Brand new shiny Suzuki day

Post by kendo57 »

We used to drill them out with a left hand drill on cars. Sheer bolts usually sheer at a fairly low torque so not
too tight. Might be worth tapping with a punch first to see if they move.
User avatar
Ditchfinder
Posts: 1037
Joined: Thu Dec 24, 2020 8:55 am
Has thanked: 563 times
Been thanked: 592 times

Re: Brand new shiny Suzuki day

Post by Ditchfinder »

The ones on my Triumph came out easy after 20 odd years. Small pilot hole then one of those screw extractor bits.
'07 Griso 1100 7 '94 Sprint 900
Bustaspoke
Posts: 1593
Joined: Wed Mar 18, 2020 5:55 pm
Has thanked: 2936 times
Been thanked: 1519 times

Re: Brand new shiny Suzuki day

Post by Bustaspoke »

Well I got lucky with the shear bolts,I took the top yoke to my mechanic mate,not to do the job but to ask him how he'd tackle it.He said they're easy enough & tried to get the bolts to move by using a sharp punch.Trouble was they weren't moving,so he took it to our mate the bike mechanic in a adjacent unit,he said not only are they shear bolts but they're also Red Locktited like the Gen 2 bikes :wtf: However as we're all matey he did the job for me there & then :thumbup:
I'd already tracked down a pair of longer throttle cables from a v low miles 2023 bike & I decided instead of re-routing the original clutch cable I'd also fit the longer clutch cable from the 2023 bike.
Whilst I was waiting for the longer clutch cable to turn up I got on with installing the longer throttle cables & the longer section of brake line from the front master cylinder.First job was lifting the air box so that I could get access to the throttle bodies.It's a bit of a pain & awkward getting to things,but everything's new & shiny,nothing corroded.
You can see wher the throttle bodies are located here

Image





Image

If you look closely you can see that there's a few differences between the cable for the X clip ons bike & the normal handlebar bike's cable.The 'X' cable adjusts near the actuator arm whilst the normal bike adjusts near the clutch lever,also the curved metal 'guide' is at a different angle,the 'normal' bike's cable is also a few cm longer.
Bustaspoke
Posts: 1593
Joined: Wed Mar 18, 2020 5:55 pm
Has thanked: 2936 times
Been thanked: 1519 times

Re: Brand new shiny Suzuki day

Post by Bustaspoke »

The extended front brake line connected behind the top tube ,here's the original.

Image


After bleeding the brakes I had to wait for the brake fluid reservoir mount to turn up.It finally turned up today

Image

I double checked all the cables for tight spots when turning the bars & as it's not been raining for most of the day I took the bike for a little spin to check everything.30 miles later & I'm happy,I prefer the bars to clip on's for the back roads around here.

Image

Image

That's it now,no more mods until I've done some decent miles on the bike,time to concentrate on riding :thumbup: