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View Full Version : 85 Suzuki GS450L Cafe Racer Build



dcastell
December 14th, 2012, 10:06 AM
Mods: Please feel free to move, not sure where this fits. Not a canyon carver or a road hog.

Never built a bike before. My previous bikes included a CBR600 and I currently ride a 2007 meanstreak.
I finished my buggy build, so now I need a winter project.


I picked this up from a retired cop for a good deal. I could have spent a little less, but he is a single dad and has a 10 year old that needed a good christmas.

It is quite a bit different going from 1600cc to 450, but I didn't know that you could turn these bad boys up to 9k rpms for the power band. I enjoyed my 40 mile ride home. Felt like dumb and dumber sitting upright and vertical.

Super clean. That is what I liked the most and it only has 5900 miles.

As she rolled in.

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0846.jpg

Started chopping and labeling wires, nuts and parts.

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0849.jpg

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0851.jpg

Plans are

Chop the rear section off and finish. Build seat (never done before) build another seat so that I can take the lady around

Rotate handle bars forward and cut to fit for cafe style ride.

Pulled all the wires out of the head light and turned the casing around so that it sits lower

Plan on lowering the gauges down about 4-5 inches. Paint the wheels black and cut front fender.

Flat black and chrome finish and hopefully a pin up girl custom paint job from my grandpa on the tank.

Never built this kind of shit before. A lot different from building a buggy. This stuff is delicate and scratches easy


As she sits now.

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0854.jpg

ZappBranigan
December 14th, 2012, 10:27 AM
Very nice. I love the mid-80's Japanese bikes.

Those handlebars are horrid, though. IMO don't waste time trying to cut or shape them, just ditch 'em. You can get a decent set of Emgo bars in whatever shape you want down at Performance Cycle for less than $20. You can even get them in black if you want (I had an 82 Spectre that had all black parts on it, had to order the bar but it was still just $20.) They have a drag bar, a "superbike" bar (my favorite) or a "Euro" bar which is just a little higher and has a little more pullback.

Or for the full "cafe racer" look you can go to a clubman bar, which they also have.

When I changed the bars on my Spectre I was amazed at how differently the bike felt and rode.

Here's the "before" with the stock handlebar:

http://i194.photobucket.com/albums/z256/ZappBranigan/Kawasaki%20Spectre/Before2.jpg

And "after" with the Superbike bar. 1000% improvement in both looks and handling.

http://i194.photobucket.com/albums/z256/ZappBranigan/Kawasaki%20Spectre/After2.jpg

dcastell
December 14th, 2012, 10:33 AM
Have any tricks to get the left grip handle off? Blow dryer, heat, or buy a new one? Thanks for the photos. I am going to go for a below neck handle bar set up. I want the bars below the neck. The tank and rake? is taller on this bike. I am trying to stick to a minimal budget. Not to save money, just to see what I can do with what I have. I will try to cut the bars and rotate, but if I fail. (Highly likey) I will buy a set. Thanks for the lead. Don't know anything about bikes. Usualy just ride them, change oil, and have a shop put tires on.

PovertyByJeep
December 14th, 2012, 11:05 AM
Take the throttle off the other side and plug the handlebar end hole (clamp a plugged heater hose over the bar). Take your blow gun and air up the left grip, while carefully sliding a flat screwdriver in from the inside. You'll probably fail, but I've managed to get a few dirt bike grips off that way. Cheaper than buying a new set- but NOT easier (and much more frustrating). Putting new grips on is an exercise in itself.

ZappBranigan
December 14th, 2012, 11:06 AM
Hmmmm...In my experience it's the right grip (the one with the throttle) that is usually too tight to remove. In any case, you can try squirting WD 40 or soapy water in there (soapy water is also a good trick to get the grips on - they will slip on easily and when the water dries, they will stay put.)

Worst case scenario, cut them off and get a new set. Again, this is a cheap part. No need sweating bullets trying to save something you can replace at very little cost.

Below-the-neck bars: That would be a Clubman. Very popular on Cafe racers in the 60's.

PovertyByJeep
December 14th, 2012, 11:06 AM
Just noticed the bike had bar ends on it- above practice will NOT work.

Dagimp
December 14th, 2012, 11:19 AM
My first and only street motorcycle accident was on a mid 80's suzuki that looked just like that. I still have the scars/divots on my knees where I rubbed off the flesh to the bones, never grew back. That was over 20 years ago.

EDIT: I guess that wasnt my first or only, it was my first and only while I was upfront. I got into an accident once while riding with my brother.

hvac_man
December 18th, 2012, 07:42 AM
I'm getting ready to start a project real similar to this, starting with a Kawasaki CSR 650. I'll have to check in here from time to time to see how your build is going! Good luck and nice start!

not so Quikjeep
December 18th, 2012, 09:30 AM
Nice I want to build one of those also. Or a bobber style bike.

csutke
December 19th, 2012, 01:17 AM
You can also use hair spray to get the grips on. That's what I did with mine and it worked great. They slid right on and once it dries it acts like grip glue. They haven't moved at all since I out them on two years ago.

dcastell
January 4th, 2013, 12:13 PM
Didn't get much done over the holiday. Spent more time on the XR-10. Been cold lately as well. Going to ramp up the work on the bike this weekend.

Seat.

Started with cardboard and pulled out some old school math for the seat. Here is the frame work. This will be metal. I purchased some wood to make the seat pan. Plan on reusing the old seat cover with some foam and staples.

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0885.jpg

On the bike


http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0891.jpg

rockrashengineering
January 4th, 2013, 03:50 PM
Nice Dan :beer:

dcastell
January 7th, 2013, 09:32 AM
Photo bucket changed the layout. See what pops up here

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0893_zpsbc1ee951.jpg

There we go.

Never ended up using my tube killers on my truggy build. So I found a home for them.

Handle bars turned out great. I will cut off the ends once I am ready. i used those to keep the balance and eye ball the level when welding the handlebars on. Turned out good. 0 dollars spent so far

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0894_zps81ee6f08.jpg

Zed Mikey
January 7th, 2013, 04:00 PM
I can't wait to see the seat finished and installed.

:thumbsup:

dcastell
January 28th, 2013, 10:18 AM
Trimmed the handle bars down. Pulled the guages off. Need to remount the light and gauges lower.

Made the seat pan. Took some phots of my ass on the bike. I am 5'9" and about 200lbs these days. This probably won't be a long distance bike for me, but it will be fun to pop around town.

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0929.jpg

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0927.jpg

Seat pan photos. Still needs a lot of work. Need to intergrate the light. I plan on making a 2" ring in the expanded sheet metal to make a glove, jacket type storage back there. Will be painted later. It is not done.

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0935.jpg

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0933.jpg

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0937.jpg

PovertyByJeep
January 28th, 2013, 12:35 PM
Looks good- did you make motorcycle noises?

ZappBranigan
January 28th, 2013, 01:44 PM
That's looking good. :thumbsup:

Colorado is heaven for people who like older motorcycles. There are thousands of them here and the dry climate keeps them from rotting the way they do in other parts of the country.

Zed Mikey
January 28th, 2013, 01:48 PM
I believe the term "fawesome" applies. :thumbsup:

dcastell
January 28th, 2013, 02:56 PM
Looks good- did you make motorcycle noises?

brappppp,brapppppp, brappapapapa......Or the sorts. I even leaned into the hard corners. The stand that comes on these things......coooool...? For now. might end up taking that thing off.

PovertyByJeep
January 28th, 2013, 03:29 PM
You will appreciate a center stand for rear wheel cleaning, oil changes, etc.

Gotta lean into the corners!

Looks really good- should scoot too!

ZappBranigan
January 28th, 2013, 05:00 PM
You will appreciate a center stand for rear wheel cleaning, oil changes, etc.

Gotta lean into the corners!

Looks really good- should scoot too!

Chain maintenance. ;)

It still boggles me that manufacturers sell chain driven bikes without center stands. I had to pay an extra $220 or so to put the c-stand on my Scrambler. Meanwhile, the 25-year-old Kawasaki I bought in 2007 (1982 Spectre 750) not only had a center stand, it had a tach, a fuel gauge, cast wheels with tubeless tires, and a seat that opened and closed with the turn of a key - none of which were available on my '08 Triumph. :rant:

But back to your cafe - I'm really liking it! What are you doing with the exhaust? Leaving it stock or going to some kind of straight pipe?

dcastell
January 28th, 2013, 05:51 PM
I am not sure what I am doing with the exhaust. The dam little holes look restrictive, but I dont want to just cut them open or straight pipe and fck with the back pressure.
http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0937.jpg

Any experience??

Insert Here .....>

lilgreenjeepyj
January 28th, 2013, 06:50 PM
Colorado is heaven for people who like older motorcycles. There are thousands of them here and the dry climate keeps them from rotting the way they do in other parts of the country.


I wish, man the costs back east were SIGNIFICANTLY less then they are here.... I would love to find an old Honda, but they are $$$$$ out here.


And I thought that Cafes didn't have center stands....:P

Navy
January 28th, 2013, 07:29 PM
http://i1281.photobucket.com/albums/a519/Navy0174/cafepipes_zps855896d5.jpg

These are the pipes my buddy put on his cafe build. If you're interested I can ask him the brand.

Rex Ashton
January 28th, 2013, 08:37 PM
Looks good- did you make motorcycle noises?That made me laugh :laughing:


http://i1281.photobucket.com/albums/a519/Navy0174/cafepipes_zps855896d5.jpg

These are the pipes my buddy put on his cafe build. If you're interested I can ask him the brand.You. Must. Do. This. :thumbsup: Those are nice :thumbsup:

I really dig the seat pan you made. Very nice job. The bike is coming out really nice. Have you explored options in moving your feet back and dropping your knees? I'm not sure what options exist in relocating foot pegs and fabbing shifter and brake lever :shrug:..... but it would make that bike so much more comfortable (at least for me) to ride. (I know, I'm not the rider :P)

Regardless, very nice job on the bike! :thumbsup:

hvac_man
January 29th, 2013, 12:09 PM
This thing is looking sweet!!

dcastell
January 29th, 2013, 04:54 PM
I thought about moving them back, but the seat is so low that I would be riding on my heals. I could move them forward, but it is still to short. I went over and took a picture on a cbr600 to see how the ergonomics looked. With the handle bars stretched down and forward it feels pretty good. I feel more confident in getting my legs down at a stop light. We will see. It has been a fun, low stress project so far

PovertyByJeep
January 29th, 2013, 05:05 PM
Ergos look ok to me. Looks similar to how I fit on my Daytona- except both the pegs and the bars are lower on the Daytona.

Navy
January 29th, 2013, 09:35 PM
Ergos look ok to me. Looks similar to how I fit on my Daytona- except both the pegs and the bars are lower on the Daytona.

Daytona 675???

PovertyByJeep
January 30th, 2013, 10:05 AM
955i

Navy
January 30th, 2013, 10:10 AM
955i

Ohh okay. Yeah I can see that a bit more than the 675 on the ergos end.

PovertyByJeep
January 30th, 2013, 10:16 AM
yep aggressive ergos for sure. BUT, they are very confidence inspiring in turns and also help to keep the front end down on hard acceleration.

Arms and legs are parallel (just like in his picture) but both angled down.

Navy
January 30th, 2013, 10:47 AM
I've always liked triumphs, been contemplating selling my gsxr for either a 675, or an 848. Enough with the thread jack though. Love the cafe build man! Keep up the good work!

dcastell
February 18th, 2013, 10:25 AM
Got he head light and guages mounted this weekend.

http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_0961_zps8c7e2dfc.jpg

Got to tuck in all the wiring back in the headlight casing.

dcastell
March 15th, 2013, 09:54 AM
It runs. This is always amazing to me once I start pulling shit apart.....I always fear it not starting again. Got the head light all back together. Seat is off to upholstery shop. Took her around the block a couple of times. Then I pulled the surveillance system to watch my self ride around the house.

WHERE CAN I WALK into a store and take a look at after market turn signals and tailights? I also need those fancy bar end mirrors.

It is a fun little ride. Feels like my old CBR600. Ride possition and comfort not performance. Still zips around pretty damn good.

ZappBranigan
March 15th, 2013, 02:34 PM
WHERE CAN I WALK into a store and take a look at after market turn signals and tailights? I also need those fancy bar end mirrors.

It is a fun little ride. Feels like my old CBR600. Ride possition and comfort not performance. Still zips around pretty damn good.

Performance Cycle on South Broadway.

There are also a couple of shops on West Colfax between Wadsworth and Garrison, on the North side of the street, can't remember the name off the top of my head.

dcastell
March 18th, 2013, 08:22 AM
Mods,

Good call on the move. The last person that posted in this section looks to be back in January. Why the move 3 months later........crickets.......

Any how. Got some cool swag from the first shop that I stopped at. Let it Ride...is the place. Got some turn signals, cone filters for the carbs, and the mirrors.
Should have some good photos on Wednesday.

ROCK BRAWLER
March 18th, 2013, 09:50 AM
Sweet cafe build! I like the seat pan you made.
I'm building a cafe racer out of a 78 kz750

dcastell
March 25th, 2013, 09:38 AM
Gots some more work done. Lights are on. They all work. Still need to put on rear tail light and license plate. Need to get seat upholstered. Any suggestions?

Here are some pictures.

http://i679.photobucket.com/albums/vv159/wampam/IMG_0993_zpsedbb5aac.jpg

http://i679.photobucket.com/albums/vv159/wampam/IMG_0995_zps4e69e9dc.jpg

http://i679.photobucket.com/albums/vv159/wampam/IMG_0996_zps51c44e64.jpg

dcastell
April 5th, 2013, 11:15 AM
Seat coming together. Now it is time for arts and crafts. Going to try and make the seat.




http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_1012_zpsb73f102b.jpg

dcastell
April 8th, 2013, 12:17 PM
http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_1016_zpsdc366ba4.jpg

Somewhat done. At least now I can ride it. I want to paing the side panels and tank a flat black. I need to tuck the wires up and out of the way. I left them open and exposed for easier access during testing.

cheftyler
April 12th, 2013, 10:33 AM
Looks great :thumbsup:

Pioneer
July 7th, 2013, 05:48 PM
http://i679.photobucket.com/albums/vv159/wampam/Suzuki%20Cafe%20Racer/IMG_1016_zpsdc366ba4.jpg

Somewhat done. At least now I can ride it. I want to paing the side panels and tank a flat black. I need to tuck the wires up and out of the way. I left them open and exposed for easier access during testing.

I think I was driving next to you today on Kipling headed north bound from Hamden north past 26th riding with a Harley. At least the bike looks very familiar except it had the plate on the inside of the fender well and it was all flat black.

dcastell
July 9th, 2013, 03:14 PM
Wasnt me. Trying to sell this guy now. I have it up on craigslist.

cheftyler
July 9th, 2013, 04:42 PM
Wasnt me. Trying to sell this guy now. I have it up on craigslist.

PM me a link?

dcastell
July 10th, 2013, 09:18 AM
http://denver.craigslist.org/mcy/3868057429.html

jeepn4evr
July 10th, 2013, 11:58 AM
http://denver.craigslist.org/mcy/3868057429.html

Lol Chicken Dinner, nice.

cheftyler
July 10th, 2013, 04:26 PM
:thumbsup:

dcastell
August 1st, 2013, 05:11 PM
Stupid Photo bucket........


Bike sold. Made a good profit and had fun with it while I had it. Don't think I will get into the cafe racing building career.