Front brake system up and working

Hello - finally managed to find some time to make some progress with the project. I've now got the new master cylinder connected to the gsxr brake system. I had to find a bit of goodridge hose with one banjo for a 7/16 x 24 harley style master cylinder and the other end to fit the 10mm Suzuki brake system.

The new master cylinder set up is great and comes with two micro-switches built in. The clutch version is the same, but is set up for a cable clutch.

Under the seat....

Ok, so now getting somewhere with fitting in the electronics. This photo shows the area under the seat, with a battery holder, a fusebox and the CDI unit. Still got to find somewhere to fit the regulator/rectifier and the starter relay.

Drilling stainless steel

I've been working on the stuff under the seat to hold the battery, fuse box, starter relay, CDI unit etc and making some plates from alloy plate. Which was fine and no problem. However life got a bit more difficult when it came to drilling some holes in the stainless steel plate - my HSS drills seemed to have little impact, so after some internet research I've getting hold of some cobolt drills. I also found out that heat, through drilling, can make SS harder so you have to take it slow and easy....hmmmm...

A short movie

There is a soundtrack with this movie, so turn up your volume (or not, if you are at work or something with no headphones!).

I've put a higher resolution version up on youtube, if you want to view that instead, as it's a bit better!

This weekend I also got the ZRX1100 back together and running, after putting in some new clutch parts to cure the dragging in gear and a bit of a rattle. The clutch is working much better now and I seem to have cured those problems, which is great. Here's a couple of photo's of that little job. Cornwall Kawasaki supplied most of the little spare parts

A sunny sunday

As the weather was good, I cleared up the garage and got the front and back end onto the bike, now that the frame is back in. Next steps are to work on the battery box and spaces for the fuse box and other electrical parts. The handlebars by the way are 31" wide custom made from 316 stainless steel 1" bars, with a set of rear slanting risers fitted to the GSXR750 top yoke. The bars are good and wide and came from 'Piggin Pipes' in Ilfracombe (who were very helpful in making a pair with the right spacing on the knurling to fit my risers).

Progressing now!

So now I have the engine mounts, I can get the engine in the frame! Hooray. And it all fits nicely.

Thanks to Ralph!

A package arrived this morning all the way from Ontario, Canada containing a whole load of engine mount parts that have proved really hard to get hold of. Thanks to Ralph in Ontario for searching these out for me - especially for the two spacers on the rear upper mount that are like gold dust!