TOPIC:

New gages arrive today !

oh yeah.

leon

is the 89 GSXR front end a mechanical speedo? Same gearing etc?
What are your plans for that?
My new front end (2004 Kawasaki 636) is not mechanical, so I have having some problems figuring that part out.

Ahhhh your 636 should be a countersproket sensor then. Man I would not even know how to start on that.

The Gixxer is mechanical, and I have to check wheel circumference from the 17" Gixxer to the 19" (stock KZ) front wheel but I will be close, and can mentally adjust as needed. Even the original KZ 900 speedometer and wheel all stock was notorious for less than accurate speedo. A gixxer cable plugs right into the KZ speedo, but is too short, so I ordered a Bandit speedo cable in the hopes it will be long enough. The KZ speedo cable plugs right into the gixxer wheel. The cables are identical, but I need a longer one.

I spent the day with my neighbor Fred soldering all the wires to the rear tail/brake and signal lights. The back end is all buttoned up. This is good feeling.

We then roughed out a bracket to hang the gages on to the Gixxer top clamp. After sawing off the ignition switch boss on the gixxer top clamp, I cut a small 3/8" aluminum plate to support the gages using two threaded bosses on the underside of the top clamp. the gages look like they were meant to be there. Now I found that the oil cooler interferes with the tach cable, so I have to move the cooler up 1 inch.

After I get this all lined up I will take the bracket and top clamp off, and massage them to look nice, and probably powder coat the two items.

Lotta lotta work !!!! It seems so close, but each step is brand new, there is no instruction manual, and no factory built this so everything is engineered as I go. That is one reason I put so much detail into this thread, so as others run into issues, maybe I have already solved a few for them.

If you are reading this and thinking of a build...its ten times harder than it looks, but well worth it.

The bracket bolted to two bosses already on the underside of the top clamp, works.

So with my little band saw, and small drill press and a couple hours with a file I finished the bracket. Then I milled a slot in the bracket so that the wires from the tach and speedo had a neat place to go. This also lightened up the bracket considerably.
I had to saw off the ignition switch boss from the Suzuki top clamp, so much massaging was needed there. Now the whole set-up looks like the factory did it.
Next I will have both the bracket and top clamp powder coated satin Black.

So many details !!

very nice!



leon

looks great! You are right, it is at least 10 times harder than it looks. But in our minds eye, the final product is worth it!
Would be nice to have a small CNC machine, lathe, drill press, pedestal grinder, right in my garage!!
Getting tired of replacing file handles!

Got the Suzuki Bandit speedometer cable, it fits !!!!!

Powder coated the top clamp... his is an 89 GSXR top clamp with the ignition boss removed, two holes drilled for the pro-

taper bar mounts, and a bracket bolted into the bottom stock bosses for KZ gages

Gags installed, hey look just like the factory did it. Eve though there is Suzuki top clamp, and most honorable modifications from Yankee Ted.