Traded my Honda Shadow for this...

[GoRacers]

I love the mirrors. They really transform the look of the bike, and are completely useable. My forearms only block about a quarter of an inch of the insides of the mirrors, so I can see 95% of the glass. Great view of what's behind, great view of blind spots with a slight cocking of my neck.

I want the largest round headlight I can find.

[turbinepowered]

What flavor of bar end mirrors did you get? Want to pick some up for my Nighthawk, my arms and elbows are just far too in the way of the stock mirrors.

[PowerDubs]

I want the largest round headlight I can find.

Keep your eye on Ebay for the Suzuki GS light then-

[GoRacers]

What flavor of bar end mirrors did you get? Want to pick some up for my Nighthawk, my arms and elbows are just far too in the way of the stock mirrors.

http://www.amazon.com/Motorcycle-Mir...ar+end+mirrors

Amazon. $19.99

[Ron L]

Keep your eye on Ebay for the Suzuki GS light then-

The '82 Yamaha Seca 650 had a rather large-ish headlight as well.

[turbinepowered]

http://www.amazon.com/Motorcycle-Mir...ar+end+mirrors

Amazon. $19.99

Ordered.

[GoRacers]

Thought the soreness in my right hand was going to go away after I got used to this bike's ergonomics....nope.

Clubman bars on the way.

Got some more mileage on her, this trans is junk. 5th makes noise like it is rubbing on the crank case on the end of the shaft, 1st doesn't like to engage from a stop, and 2nd is useless for anything other than carefully getting from 1st to 3rd.

Other than that, LOVE THIS BIKE.

[turbinepowered]

Keep your eye on Ebay for the Suzuki GS light then-

I laugh that you speak of the Suzuki GS and show a picture of a Kawasaki.

[PowerDubs]

I laugh that you speak of the Suzuki GS and show a picture of a Kawasaki.

I laugh that you don't realize that is a Suzuki GS headlight on a Kawasaki that comes from the factory with a square headlight.

We are talking about swaps after all, aren't we?

[mrothwell]

I laugh that you don't realize that is a Suzuki GS headlight on a Kawasaki that comes from the factory with a square headlight.

We are talking about swaps after all, aren't we?

I laugh too though, because the ZRX looks soo much better with the little bikini fairing that it originally came with.

[PowerDubs]

I agree. That's not my bike.

The prior owner on mine had put on dual lights such as on a speed triple. I put the stock setup back on.


- Josh

[GoRacers]

Engine coming out on saturday in preparation for trans replacement.

Got a good deal on a used, already modified gear set from a member at xs11.com.

[PowerDubs]

Ever split cases before? Fun fun.

Unless you are proficient, I'd wait until winter. The best time of year to ride is almost upon us.

[turbinepowered]

Ever split cases before? Fun fun.

Unless you are proficient, I'd wait until winter. The best time of year to ride is almost upon us.

This. Unless you're spitting chunks when you drain the oil, let it ride for a while until you get out of the pretty season.

[nhbubba]

I laugh that you speak of the Suzuki GS and show a picture of a Kawasaki.

Try this then:



'01 Suzi Bandit 1200 (aka GSF1200K), factory headlight, (****ty) aftermarket screen

That kawi wears it better though. But where the hell are his signals? No way that'd get a sticker 'round here.

[GoRacers]

Ever split cases before? Fun fun.

Unless you are proficient, I'd wait until winter. The best time of year to ride is almost upon us.

That's the whole point; I can't feel good about riding the bike when 5th gear makes the noise it does. I'd feel very irresponsible rolling the dice and riding a bike with a questionable transmission.

I was going to just live with a crappy 2nd gear until the winter, but not with 5th making noises like it is machining a new groove in the case.

This bike will be ridden again this season, I promise.

[GoRacers]

Pulled the engine with a good friend/coworker today after work. I will be buying an engine hoist to put it back.

It is even heavier than it looks.

There are so many things I want to do while the bike is apart, but I want to ride it as much as possible for the rest of the season.

The list of what WILL happen while the bike is apart (this time):

paint or wrap exhaust
clubman bars
media blast engine/trans
full transmission swap (donor parts have had the "dremel fix" already performed as preventative maintenance
front brake master cylinder
oil level switch on bottom of trans (currently leaking)


The list of possible tasks is:
delete rear fender and integrate brake light and plate into rear seat section
paint frame
round gauges (currently working on getting parts)
round lights (currently working on getting parts)

Weather lately is absolutely PERFECT. Very upset that I cannot ride currently, but am hoping that it motivates me to get this thing back on the road.

[Knock Sensor]

I'd just get it done, the motor is out so go nuts while you've got it out. And best of luck putting it back in, I pulled the motor on my xs750 and it was all kinds of stupid heavy. Ended up using a rachet winch attached to the ceiling to put it back in easier.

[GoRacers]

I'd just get it done, the motor is out so go nuts while you've got it out. And best of luck putting it back in, I pulled the motor on my xs750 and it was all kinds of stupid heavy. Ended up using a rachet winch attached to the ceiling to put it back in easier.

Bought a hoist today. Waiting on parts now .

[GoRacers]

Thick, muddy crap in the oil filter, oil filter housing, and oil pan.


I hope those are bits of transmission and not engine internals....




I haven't decided whether I'll be swapping in the entire replacement trans, or just 2nd and 5th gears. If it can be accomplished without splitting cases, I'll do the whole trans set. If cases must be split, the 2nd and 5th gears will be swapped to get me to the winter when I'll tear her down again for paint and clean-up.

Scored a front master cylinder on eBay for cheap

Clubman bars order was cancelled by Amazon, out of stock. Ordered another set, also on the way.

[turbinepowered]

You'll have to post pictures with the clubman bars. I keep considering a set, maybe with some risers, to get the same low position I have now but with better tank clearance.

[GoRacers]

Got the drive axle and gears out last night.

The dogs on 5th that mate with 2nd have definitely already had the "dremmel" fix done.....but I don't think it was done right. The dogs are SEVERELY back cut (dovetailed), I don't think it's possible for them to mate on a flat surface with the slots in 2nd gear.

I also don't think the gears are installed 100% correctly on the axle. Looking at the diagram now (don't have the parts with me), I feel like there may have been a circlip missing on my transmission between 5th and 2nd. I can't remember right now, I'll check that also when I clean the parts up.

I didn't see anything I didn't like about 5th gear or the inside of the casing on the drive axle....what else should I look for that causes the 5th-gear grinding noise (very light) on the freeway? I'm more concerned about this than the 2nd gear issue...

I'll take some pics after I degrease and clean up all the parts so I can better inspect them.

[GoRacers]

5th gear dogs...



Slots on 2nd gear...



Seems that 5th gear was contacting its shift fork...


5th gear has irregular chamfers all the way around the edge, makes sense since it was contacting the fork...


I can't tell with my eyes whether the fork itself is bent, they don't have a very uniform/precise shape to them to begin with. I am replacing the forks with the ones coming with my parts transmission.

[benjaminobscene]

Lol the guys on TV make it look so easy to just bear hug a v-twin into the frame

[GoRacers]

Lol the guys on TV make it look so easy to just bear hug a v-twin into the frame

I consider myself a decently-strong dude, and I wouldn't R&R this engine/trans by myself.

[GoRacers]

Amazon cancelled my order for clubman bars AGAIN due to the vendor being out of stock. Ebay to the rescue. Ordered black bars this time.

New front master cylinder installed today. Removed front fender, also.

Transmission getting here Monday, girlfriend out of town next weekend. Hoping to get it back on the road. I may just sleep in the garage hahahahaha.

[GoRacers]

Clubman bars installed. Bummed about the fitment of the OEM front master cylinder, it contacts the gauge and still needs to come about 1.5" further up the bar for the throttle to install flush with end of the bar.


As long as I like the way the bars ride and handle, I'll buy a smaller form-factor master cylinder to fix this issue.
Sad bike. :


Work space:





Got the gears modified and installed on the countershaft, ready to put back into the case tomorrow.

I'm hoping to ride this thing Sunday.

[EdRacer71]

if you are still looking for a round headlight....SV650N and SV1000N headlights can be had for cheap on ebay. My VX800 came with the standard glass GS headlight, and I swapped over to one of the SV lights. HUGE difference in lighting even with only a mild wattage bulb in it.

[drumonay]

that kawasaki is gorgeous... what is it?? I know its got that suz light on it but is the rest alot of custom work too??

[EdRacer71]

that kawasaki is gorgeous... what is it?? I know its got that suz light on it but is the rest alot of custom work too??

ZRX1100/1200. Headlight, pipes and bar end mirrors look like the only things swapped from stock. I am actually thinking about one of these for my next bike.

[PowerDubs]

Not to thread jack, but the ZRX are great. I bought one a few months ago.

Here is a writeup on them- http://www.motorcycledaily.com/2001/...i2001zxr1200r/


You can find them in good shape for between 3-4k depending on mileage.

[GoRacers]

Shifter linkage was mis-aligned the first time I put it back together, so I was pretty bummed out and thought I had to do the trans job again. Fixed the linkage and we are good to go.

This bike hauls ass with a working 2nd gear.

Clubman bars really help the bike. Feels much more nimble and less like I am just along for the ride on top of a 600-lb freight train. Turning radius is still fine, but the bike is a bit much to manhandle around and do a 3-point turn to turn around in the garage; have to remember to back down into the garage when I come home. I think I'm just barely tall enough to maneuver the bike with bars this low.

Still need a good front brake MC, my new one leaks as well.

Want a round headlamp and gauges, and a new tank. Those things can wait, though.

[Knock Sensor]

Looking good.

[turbinepowered]

Looking good.

Looks great. I have GP bars on my Nighthawk right now, considering some clubman bars. May be able to get some tank clearance back; your clubman bars are set forward, right?

[GoRacers]

Looks great. I have GP bars on my Nighthawk right now, considering some clubman bars. May be able to get some tank clearance back; your clubman bars are set forward, right?

Yes, set forward