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Discussion Starter #1
Since it's been too hot in the Houston area to do much of anything lately, I've decided to do my winter customization early.



When I bought my bike, it had taken a bump to the headlight cowling and dash bezel. I converted to a round headlight with fleabay headlight mounts.



...tried using a Trailtech Vapor unit, but missed the analogue guages.











Ordered a new OEM dash bezel and warning light box and changed to CR high bend handlebars with risers.







New bars made it much more comfortable.



I'm looking for a more street or polished look, so tore my bike down to the bare frame and started the cleanup and customization.



..scrubbed the motor down with simple green, then Dawn. Let it dry overnight. Then sanded the clutch and oil filter covers to a bare matte finish, same with the cooling fins.







Did the same cleaning on the frame, plus some degreasing ...then mounted the engine back into the frame.

I thought it might need some paint, but it was just really dirty.








I've ordered the exhaust from an 81 SR185 from fleabay and am waiting to do some test fitting. My plan is to use the the SR header and a custom muffler. The 81 SR185 engine is very similar to the Tw's and uses the same exhaust gasket, so I expect the header to fit.
 

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I like the look of the sanded bare metal finish look on the engine, particularly the engine fins. Has a fine look to it and gives the engine a whole new look. I may copy that during some winter down time. Nice job!
 

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Nice work, so far.



Send me that nasty old Vapor...
 

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Dumb question number 287,541



Won't sanding down the cases open an invitation for rust?
 

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Josh is sneaky dat way
 

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Your engine looks great, nice job!
 

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Discussion Starter #9
Well, the SR185 pipe fits the head perfectly, but the bend doesn't hang low enough.



I cut the muffler off the header and installed it, but if I run the pipe close to the engine it hits the brake lever.







I might try to run it out like it is with a shorty muffler and see how it looks, but I'll probably end up cutting the pipe and running the pipe under the engine and angling the muffler like the Beams setup.











Once I get the pipe situated it will get cleaned up and either polished or wrapped..haven't decided.



Next is fork service/fluid change...
 

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Dumb post removed by dumb poster. Carry on.
 

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hey brock



they are aluminum, no need to worry


Aluminum does oxidize. Most engines with what looks like bare metal actually have a high temp clear coat.
 

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Any special tips for anyone wanting to getting that sanded finish on their engines? It looks really slick!
 

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Discussion Starter #13
I used an orbital sander. It's kinda tough to get the texture uniform, but not that bad.



First thing I did was get the edges even, so it would be as close to a perfect circle as possible, then sanded the rest of the area with almost NO pressure. Let the sander do the work-

aluminum is pretty soft.

After it's bare, just take it easy with the sander and use fast/broad movement of the sander to even out the finish.



I'll check the grit of the paper I used later tonight.
 

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Discussion Starter #14
I added some spacers to the forks made from threaded Sch 40 PVC. The threads made it much easier to get them even. I sanded the bottoms to finish them out.







I used Mobile 1 Synthetic ATF instead of fork oil. It's very similar to the recommended Yamalube 10W Fork Oil.



To set the fork oil height, I used a digital caliper. Set it to 5.31mm and used the depth measuring end.







I wasn't happy with the way the SR185 pipe looked so I used it and the stock header to make a new pipe. I went with a little different angle than the usual 90 degree bend. I haven't put

on a muffler yet. This build is on a really tight budget. I am probably going to use a universal fleabay muffler. Hopefully it isn't to obnoxious to ride a little before I get the muffler...

I still need to fnish the pipe out, paint it and wrap it.





 

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Discussion Starter #15
I finished cleaning up all the parts and put a muffler from a 97 cr125 on. Without a muffler, it was WAY too loud to ride.



I still need to do something with the rear fender and brake light area, I think it sticks out too far now.



I put it back together to get some riding in, but there is still more work to do.











The spacers in the forks and Mobile 1 Synthetic ATF worked great. The suspension feels more balanced now and the forks feel less mushy. It helped with the braking nose dives also.



The muffler is about as quiet as the stocker, maybe slightly louder. It seems much louder while riding because the muffler is right under me, but if I lean forward I can barely hear it.

The new exhaust shifted the powerband toward the middle of the RPM range. I noticed a drop in top end power, but a good boost from lower mid to upper mid. Low end seems the same.



It will get up to 55 quicker and hold it- even with a good headwind, but then power drops and getting beyond 65 seems impossible. It also sounds much more "relaxed" at 50-55 now,

like it could run all day at that speed.



Thanks for all the compliments. I'll add more as I make changes.
 

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Discussion Starter #17
Finished the header with an angle grinder. Used a stone disk first, then an 80 grit sand paper disk to smooth everything out. Coated in VHT flat black header paint and cured per the directions on the can. Seems

as tough as the OEM header coating once cured.



Also mounted the storage tubes back on, which filled in the space out back some.









Here is a video of it running. With the muffler packed with 4 stroke FMF packing, it's suprisingly quiet, for being what it is.



http://dl.dropbox.com/u/9481139/IMG_0637.MOV



I need to sort the jetting. After riding it a couple more times, I've found it's too lean in the upper RPM range- explaing the sharp drop in power in the upper end of the RPM range. Though, with the big peak

I've gained from the bottom to upper midrange of the throttle, I haven't found it necessary to wind it out nearly as far as before during hard excelleration (well, hard for the TW, lol). It's mostly noticable

when revving it with no load and under decel.
 

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Discussion Starter #18
Anyone know of any fork dust seals that will fit the TW forks? YZ80 looks like it would, but not sure....
 

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If you want something sleek and not accordian-like OEM boots order Suzuki Part Number: 51173-41603. About $11, but you may find them cheaper elsewhere.
 

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Discussion Starter #20
Thanks! That will save me a bunch of time and $$ trying out dust covers.



Thanks exactly what I was looking for. TW needs a dust seal, just not fond of the accordian boots.
 
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