DJ's new project bike

I

illiniguy

New member
Some unexpected money has come our way so I've been given a $1000 budget to use to do whatever I want with the S40. Apparently the wife felt a little bad that I sacrificed getting a new bike now in order to pay off some bills. So I've started on some heavy modding.
S4020103.jpg


Tomorrow I'm taking the rear fender to my brother-in-law's body shop to get all the screw holes filled and the fender repainted. I'm gonna do the cat eye rear tail light under the back of the fender. I've also got 4" forward controls and a 29" broom stick handlebar ordered. I'm gonna lower it too while I've got it raised on blocks in the garage.

When I get done it will look a lot like this bike:
coolbike.jpg


I've also found a lot of rave reviews and proven performance results about Lancer's carb + cam performance kit. The typical results are an increase to 45hp and 42 lb/ft of torque, 0-60mph in 4.9 sec, 1/4 mile in a respectable 14.2 sec @ 89 mph. That's just over a full second faster in the 1/4 mile than my M was. There's a lot of history on this kit so the data looks pretty accurate and reliable.
 
Just dropped off the rear fender to get the holes filled and just ordered the cat eye LED tail light. I got the K&N pod filter for it this morning. I'm waiting for the jet kit to come then I'll put it all together. Got to go buy the local harley shop and get a sportster muffler that will bolt right on.

For broomstick drag bars, I can only find the unknurled (when knurled it's for HD and will show between the riser clamps) and undimpled bars in 29" length. They usually run about $65-$75 + shipping. I want it just a tad longer. I've found some sites where I can order a 1"x40" stainless steel pipe for $20. I'm gonna investigate that and see if it will work. If so, I'll cut it down to 30-32".
 
Smyrna is right outside of Nashville to the Southeast.

Stripped down like that is looks like a bicycle :) Did you take a before picture?
 
I like the pink bow. I was thinking of replacing my Leathal Threat skull with it. :)

I have been wanting a half helmet to replace my 3/4 helmet. My wife wants me to wear a full face. Well she did find a pink half helmet with flowers she has agreed to let me buy. (I passed)
 
On the highway I ride with a full face, partly because of the safety thing, partly because MAN A BEE HURTS AT 60MPH!!! and partly because my communicator and mp3 player are set up in it.

For scooting around town, I have a half helmet and as someone who wears glasses, I'll have to say, riding in the rain in a half helmet and not being able to see out your friggin glasses SUCKS!!
 
That is one of the reason I want a half helmet to get aound town. I got a close up veiw of a butterfly the other day on the interstate, and at 70 MPH I was glad I had that sheild.
 
You're close then. The wife and I go to Nashville a good bit. We'll have to hook up sometime.


Hey, it's a true project bike! I've got a lot to change on it. Good thing I can do a lot of DIY cause it saves tons of $$$.

Jason, Here's the before pic:
S4020076.jpg


I'd love to do this:
2407_0original.jpg

From stock it's pretty much fenders, tank, seat, paint, forward controls, muffler and lighting. All of which are very do-able. I'm gonna work on the seat. I've already got the forward controls on the way and muffler in the garage. The lighting will be half done and I found the risers I'll use. But that total package will be next year's side project. Right now it's all about maximizing performance and cleaning up the back end.

You know, I pretty much used to blow off the S40 as small, underpowered, beginner bike, etc. I've developed a new respect for this bike. With very minor tweaking, the performance numbers of this bike are quite impressive. It's the same engine since the mid-80's but instead of routinely redesigning the engine to meet emission standards, Suzuki basically kept adding restrictive measures to meet standards, resulting in the less than impressive advertised performance numbers. All of these changes are very easily undone and then improved upon. The result is performance that is on par with about all middleweight cruisers. The engine, gear box, frame and belt drive are pretty much bulletproof and very easy and cheap to repair if needed. I can find parts all day on ebay at awesome costs since the bike has been in production for the better part of 20 years. There are also so many parts, like yamaha wheels, honda fenders, HD mufflers and kawasaki tanks that are basically direct bolt on that people have used. It's freaking amazing!
 
We go up 65. I live about 5 miles off of 65. We go up 2 for Chattanooga. I did go up a little further to Cleveland to see a buddy of mine a few months ago.

Loki, I usually am missing one or two- never any left over. Good thing I've got one of those cool mom & pop hardware stores right up the road. It's one of those places that is small yet always has what you need.
 
I finished cutting open the airbox (since I don't need it anymore). I put it back on and am using it as a nice dry place to stash the main wiring connectors, rectifier, relay, etc. The battery box with battery is back on too.

Tomorrow, I'll change out the pilot and main jet (going from the 145 stock to a 155), install the carb and then the K&N pod filter. The pod filter will fit and breathe better now that I've reshaped the airbox and have given the pod filter more room. I've already done the white spacer and idle mixture mods to the carb.

I'll also fab a small bracket to mount the sweet sportster 1200 muffler that I got for $20. HD dealers have them cheap. It's a pull-off from a new sportster 1200 where the new owner wanted a different exhaust setup when he/she bought it new.

Intake, carb and exhaust will all be done then. Can't wait to eventually put it all together and try it out. I'll keep it on blocks til I get the forward controls on, the custom rear fender on and the custom tail light and rear turn signals all set.
 
Made a bracket and got the sportster muffler on. It's half the weight of the stocker.
S4020111.jpg


Much better than the big, clunky, heavy, restrictive device they call a muffler.
S4020103.jpg
 
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