TOPIC:

i got the cover and the lockup and the spacer from you.

madkaw1200 wrote: i got the cover and the lockup and the spacer from you.

Yeah, I knew the cover and spacer....didn't recognize the snowflake lock up...can't remember having that!

Got the brake discs painted....hoping the gold won't be too much....should match the black and gold paint pretty well and they don't really show a whole lot anyway, especially the back one.

79MK11... you using spray can to paint disks?
nice project...

spdygon wrote: 79MK11... you using spray can to paint disks?
nice project...

Yes, it's engine enamel with ceramic....rated to 500 deg F. I'm thinking it should hold up to the heat pretty well. I also baked them to make sure they were fully cured.

ok.....so should of ask this on the last post...
did you take apart the disk ( if you did how do you do it ) or did you just do a great tape job?

I wanted to take them apart but I think they are assembled permanently. Some floating rotors have circlips that pull off but these appear to be kind of riveted, I guess. No way to take them apart and get them back together without all new hardware and a special tool. So, I spent a lot of time masking:

Yep, as much as I am embarrassed to say...I did...I prematurely shot a load off in my pants. Never thought that I would ever be considered less than a two stroke bloke but there it is.

madkaw1200 wrote:

here it is.

Project is moving along, although much more slowly than I'd like. This "simple" GS conversion has been alot more difficult than I thought it would be. I've pretty much had to do everything I would have with converting any other swingarm...nothing has been "bolt on". Here's a shot with the wheel installed:



The upper shock bushings were the wrong size so I had to press out the old ones and I installed a pair from an old set of KZ shocks I had. The rear brake bolt hits the swingarm (where the brake pedal bolts to the brake rod that goes to the master cylinder) so I bent the tab on the pedal and will reverse the bolt because the castle nut is smaller than the bolt head and gives me a little more travel before contacting the swingarm. I had custom SS braided brake lines made up for the whole motorcycle because a dual disc conversion is in the plans for the front. Got all (4) lines custom made for under $100. Also did the final trim on the inner rear fender to clear the swingarm and brake arm mount. Few more pics:

Modified inner fender:


I added a few spacers to move the top of the shocks out a little more since the GS swingarm is wider:


Couple shots with wheel, shocks and caliper installed:




Also had to shim the brake arm to the KZ caliper:

Started installing the new 530 chain and sprockets. Got the trans cover cleaned up:



Got the brake line installed with a gold anodized banjo bolt at the caliper....will use the same on the front calipers when the time comes.

I have the wheel perfectly centered in the swingarm and guess what....the sprockets don't line up! I think the wheel was laced a little differently than factory even though I used a stock KZ hub. The rim seems to be a little offset to the right. This would normally be great as it would help the chain to clear a big fat tire, but I chose a 3.5" rim with a 150mm tire so I wouldn't have any clearance issues. Now I have to align the sprockets, so I have ordered a 1/4" offset front sprocket. Yep, another part of this simple bolt-on mod.

A general question to everyone....what on earth is this weld nut for? I have owned several bikes now that were 100% original and I haven't seen it used for anything. I used to think it was somehow used for the stock airbox or tool tray but it isn't. Anybody know?