Suzuki2Strokes.com

Sundial Moto Sports

Suzuki Two-Stroke Message Board
Suzuki2Strokes.com
It is currently Wed Sep 26, 2018 1:54 am

All times are UTC - 6 hours




Post new topic Reply to topic  [ 50 posts ]  Go to page 1, 2, 3, 4  Next
Author Message
 Post subject: TS185 cafe racer
PostPosted: Sat Jan 03, 2015 6:36 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
another long-term project of mine..........

A USA-import TS185 in not very good, or complete, condition.......

Image

Image

as standard, the TS has a cable-operated rear brake. Obviously searching for more "feel" from the brake, a previous owner has converted it to rod-operated, albeit the rod is a tad too short. Not a problem to a genius bodger though...............

Image

and the rear brake arm bolt.....................

Image

sheeeesh!...................

had a rummage around the garage for some different handlebars - don't like the American high-and-wide ones that came with the bike. Couldn't find anything suitable, but did unearth a set of TS185 clocks I bought for the TS400 resto, so put these to one side for now...................

Image

Went and had a rummage around my mates garage and found some suitable 'bars - much more European............

Image

see where this is going?............................ ;)

back to the clockset - I only need a speedo so set about modifying the bracket that came fitted to the bike. Here's 2 standard brackets...............

Image

the top one I have cut to size and measured and drilled 3 holes for the clock rubber-mounts and speedo cable connection. This is whats left..................

Image

and with the speedo mounted............

Image

Image

and fitted to the bike...................

Image

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Last edited by garry55 on Sat Jan 03, 2015 7:03 pm, edited 1 time in total.

Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Sat Jan 03, 2015 6:42 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
the cafe-race seat - I didn't have one in my garage, so had to buy one off t'bay................

Image

I chose this one as it has an undertray.............

Image

the new seat wouldn't fit, as expected, without some minor surgery to the frame. First to go - the rear frame loop..........

Image

Image

then the cross brace...............

Image

and - oh the irony of it - the seat mounting brackets..........

Image

even then, it didn't "sit" right, so time for some major surgery.............

Image

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Sat Jan 03, 2015 6:47 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
the seat also required a bit of trimming..............

Image

Image

bit of tidying up required............

Image

which allows it to fit like this...............

Image

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Sat Jan 03, 2015 6:48 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
Image

filed a notch in the side of the seat unit to clear the exhaust mounting................

Image

with the leg-warmer fitted...............

Image


off with the bash plate - it's off-roading days are over (I hope!)..........

Image

the alarming lean angle afforded by the standard sidestand.............

Image

a rummage in the toy box ellicited an aluminium Cagiva Mito stand left over from the RGV build - and the TS185 stand bolt is an exact fit - lucky me!.................

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Last edited by garry55 on Sat Jan 03, 2015 6:56 pm, edited 2 times in total.

Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Sat Jan 03, 2015 6:52 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
ah - thats better..................

Image

and lighter too!..............

Image

another rummage in the toy box and out came an RGV250 kickstart and - would you believe it? - an exact fit................

Image

the new shocks arrived - these "Rarelins" make Ohlins look like economy shocks 8-)

Image

Image

My error - I forgot to specify the diameter of the mounting bushes so I received the default 12mm upper / 10mm lower bushes fitted. The mountings on the TS are 12mm upper and lower, so I pressed the lower bush out and, on a very slow speed (necessary when turning Titanium), bored-out both lower bushes to fit.

Image

Image

Here's some technical spiel from the spec sheet.......................
"the body is milled from a billet of Hastalloy (melting point 2417 - 2498 degrees celsius, with a density of 554.98 lb/ft). The damper rod is Inconel 625 grade which has an unsurpassed shear strength of 220,000psi. The remote cylinders are charged with a degenerative quantum gas of the Fermi family of high density, super-cooled atomic gasses. Springs are of Titanium and made to customer specification with regard to rider weight and intended use.













£80 a pair off ebay.......................... :up:

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Sat Jan 03, 2015 7:01 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
another ebay bargain - new 7" headlamp unit that comes with 17mm mounting holes but no hardware.............

Image

Image

so I turned a pair of these 17mm top-hat spacers, drilled with an 8mm hole to accept the mounting bolts and fitted to the shell.................

Image

then, with a subtle tweaking of the original headlamp brackets, to the bike...............

Image

Image

more from the rummage box - Cagiva Mito throttle-side switch gear, modified to suit left-side operation..............

Image

kill switch, lights off / lo / hi and the starter switch becomes the horn button - no turn signals needed.

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Sun Jan 04, 2015 1:56 am 
Offline
World Superbike
User avatar

Joined: Thu Feb 16, 2012 11:50 am
Posts: 2146
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
Nice little project that. Those shocks look the biz.
Have you got a lightweight person in mind to ride it or will you sidecar gear it? :roll: :lol: (Lets me out as well!!)


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Sun Jan 11, 2015 12:17 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
I am that person you mention, Al :up:

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Thu Jan 22, 2015 3:53 am 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
the bike returned to my garage last night, so I spent most of today tinkering with it.

First off though, the mods made by my welders.

The new rear frame brace / mudguard mount

Image

and the front brace / seat mount

Image

the custom 2T oil tank bracket and strap

Image

rear mudguard extension so taillight can be accomodated

Image

Image

like so

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Thu Jan 22, 2015 3:54 am 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
so back to today - first off, I made a pair of front mudguard brackets out of some alloy sheet

Image

I'm thinking of drilling some holes into the parts of the brackets that show either side of the fork legs to reduce the "solid" look they have now.

Then I fitted the fly screen

Image

modifying the brackets to prevent the screen from being blown back at high speed :)

Image

with no bracketry for mounting the electrics, the rectifier now sits atop the air filter box

Image

and the CDI lives under the seat

Image

the battery will be housed in the seat hump.

and everything loosely fitted in place

Image

Image

Image

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Thu Jan 22, 2015 3:55 am 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
the freshly built motor - re-con crank, all new seals and bearings, rebore and new piston.
Crankcases were de-greased and attacked with various Scotchbrite pads whilst the head / barrel / outer casings paid a visit to the powdercoaters to have a coat of satin black applied.

Image

Image

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Thu Jan 22, 2015 1:01 pm 
Offline
World Superbike
User avatar

Joined: Thu Feb 16, 2012 11:50 am
Posts: 2146
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
Coming on nice.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Thu Jan 22, 2015 2:49 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
cheers Al :up:

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Wed Jan 28, 2015 12:13 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
today I drilled a hole in the 2T oil tank bracket for the outlet

Image

so I could mount the tank

Image

and test-fit its retaining strap

Image

then I drilled 3 holes in the headlamp shell

Image

and fitted the idiot lights - neutral /main beam / turn

Image

whilst the drill was out, I attacked the front mudguard brackets too

Image

and as the heat shield had arrived from the USA, I test fitted that too

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
 Post subject: Re: TS185 cafe racer
PostPosted: Tue Feb 10, 2015 2:19 pm 
Offline
To the on ramp
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
received my "custom" graphics courtesy of the Image Works today.

I asked them to replicate the standard TS185K gas tank graphics, as shown below.....


Image


but to change the colours so as to emulate the early Suzuki racing bikes scheme..........


Image


The colour is a bit dull as they still have their protective outer film applied, but powder blue with a black outline on a gloss white gas tank it is. I'll have a matching stripe painted onto the seat hump.

Well pleased :D

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


Top
 Profile  
 
Display posts from previous:  Sort by  
Post new topic Reply to topic  [ 50 posts ]  Go to page 1, 2, 3, 4  Next

All times are UTC - 6 hours


Who is online

Users browsing this forum: No registered users and 2 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  
Powered by phpBB® Forum Software © phpBB Group
Sundial Moto Sports forum © by Eric F. Kalamaja
Suzuki2Strokes.com