"Operation Ugly Suzi" - 1988 GSX600F rebuild

[eddclarke]

Following on from this thread:
https://www.bikechatforums.com/viewtopic.php?t=239894&start=25

I will be using this thread as a diary of what has been done to this bike. The goal is to get it on the road and use it as a reliable commuter.

Here is how it looked when I got it back to mine


https://cdn.bikechatforums.com/files/suzi_114.jpg

https://cdn.bikechatforums.com/files/suzi2_120.jpg

The first job that I had to do was get shot of that headlight!

Second job was connecting up a battery and seeing what happens... the lights all work but there is a loud clunk when I hit the starter. I think it may be down to a dodgy connection somewhere (the bike has been stood in a shed for a couple years). Any advice would be very appreciated!

The list of bits to do is as follows:
Trace electrical fault
Fit new headlight unit
Strip and rebuild front and back brakes (the front master cylinder was full of nuts and bolts )
Fix the hole in the side of the tank/replace tank
New clutch perch needed
New C&S
Polish the wheels
Paint engine case
and a million other small jobs...

Here is how it stands now:

https://cdn.bikechatforums.com/files/3_146.jpg

https://cdn.bikechatforums.com/files/4_278.jpg

As you can see, the frame is in good condition!
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Honda XR125L 06 ----> Yamaha FZ6 05 + ex SAS XR250 --> VFR800 + XR250r

[Gazdaman]

Starting problem probably is an electrical connection related to the starter relay or solonoid. One way to find out if it's anything more serious would be to try and bump start it.

And good god that bike's hideous.

Gaz

[Ichy]

Can I just suggest that before you do anything else that you take off the timing cover and try and turn the engine over by hand?

Does the neutral light come on?
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https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[eddclarke]

[nickyboy4]

Bought and sold t
one of these last year with a starting problem, turned out to be the right hand switchgear, you can use a bandit one because there are more of them around!