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2003 Roadstar 1600

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  • 2003 Roadstar 1600

    Here's my 2003 roadstar 1600
    I guess it gives the term "Hand shift" a whole new meaning


  • #2
    Ouch!....if you ever get tossed over the handlebars and impaled!
    “The West is the Best" - Jim Morrison

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    • #3
      Representing Scorpion Gulch, Arizona. Looks like it still has a hand clutch. How does that work? Do you have 2 left arms?

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      • #4
        I’ve been thinking about adding a foot clutch and hand shift to my Springer. I was tempted when I added the Springer, but got to the point I just wanted to get it on the road.
        Maybe this summer.

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        • #5
          Originally posted by Father Pobasturd View Post
          Representing Scorpion Gulch, Arizona. Looks like it still has a hand clutch. How does that work? Do you have 2 left arms?


          when up shifting i usually just use my left hand with no clutch
          When down shifting I just pull the clutch with my left hand and shift with my right

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          • #6
            Originally posted by Shores View Post
            Ouch!....if you ever get tossed over the handlebars and impaled!
            The fairing is made from some old 16g sheet metal I had laying around
            the top part is so thin It will bend with the slightest nudge
            I actually broke the plexiglass windshield yesterday on accident so I will be redesigning it soon

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            • #7
              A few upgrades have been done since my last post
              I grabbed a new oem intake manifold online (appeared to be somewhat ported compared to my stock one)
              Got it for only $60 shipped which was the cheapest I could find
              Installed a maier fairing and a 7 inch headlight
              Installed a new air filter I grabbed from autozone
              Changed out the shift knob and grips
              Installed the baron jet kit (pretty much just the adjustable needle since I already had the jets)
              The needle install was a considerable upgrade as far as throttle response
              Replaced my enricher cable/ knob
              replaced the cracked coasting enricher cover

              Next on the to do list is to fabricate a new sissy bar
              make a new seat
              repair the rear fender some more (dang vibrations keep cracking it)
              replace the stock rear spring
              Get the springer fork finished up and installed
              Attached Files

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              • #8
                Wow, that is one cool @ss ratbike! Scare the hell outta little ol' ladies and young children.

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                • #9
                  A few updates so far
                  I managed to get a 4.5 gallon king sportster tank for a pretty good deal ($100) no rust, just needed some paint and a new petcock
                  Made some mounts for that and got a good sanding into it along with some clear coat
                  I redesigned the shift lever to accommodate the new tank/ shifter knob
                  i also found a baron velocity stack at the same motorcycle swap meet, new in the box and I only paid 30$<--steal of the day

                  Next on the list is to fix the rear fender (more support since it cracks)
                  Then a new sissy bar
                  And after all that a new king and queen seat with a fiberglass seat pan

                  Hopefully some time after that I will be able to weld up the exhaust into a 2 to 1

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                  • #10

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                    • #11
                      https://www.youtube.com/watch?v=_u5QSIrgjjU

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                      • #12
                        There's a quick walk through of my bike, I would have revved it but the kids where sleeping
                        In the process of making a new set of pipes from some mandrel bent pieces
                        The swingarm bag is made by leatherworks inc if anyone was curious

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                        • #13
                          The exhaust size without the heat covers on it is 1 3/4" if anyone is wondering
                          The pipes that came on my bike where cobra slash cut drag pipes but they where too long and scraped around every corner so I decided to make a set of my own with a little more ground clearance
                          without the heat covers on I was able to pull the flange right off and copy a template of it to make more, I can measure and scan the flange if anyone else is interested
                          The pipes have a collar on it where the flange attached to it , stepping it up from 1 3/4" to 2", it is then flared flat to mate up with the exhaust gasket
                          To make the collar I just got a piece of straight 1 3/4" pipe from autozone, one side had a flared female end, the other was the standard 1 3/4", I cut part of the flared side off, slipped it over and welded it to the male side, i then cut a few more slices of the flared side, cut them in half, and made them fit over that which gave me the size I needed
                          Welded it all together and it fit perfectly on the bike, now to just cut out all the mandrel bent sections I need and learn how to tig this blasted thing steel!

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                          • #14
                            Here are pictures of the stock pipe as well as some shots of the process, I didn't get a picture of the split rings I had to make to simulate the final flat flange on the pipe collar but you get the idea
                            Attached Files

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                            • #15
                              Building the lumber luggage rack was pretty fun since I hardly ever work with wood (see update video)
                              I ended up mounting it to the stock sub frame with the normal 4 mounting bolts the fender normally goes in
                              I usually end up carrying 1 or 2 backpacks with me on the weekends to carry stuff I find at local swap meets so this will allow me to have some time to weld up the rear fender cracks as well as reinforce it
                              In order I plan to:
                              Finish the exhaust pipes
                              Replace the stock front brake reservoir with a lower profile nissin 5/8 "tube" reservoir
                              Repair/ reinforce rear fender
                              Design and make a new sissy bar from some 5/8" steel
                              Re design the tank mounts
                              make a new fiberglass king and queen seat pan/ upholster it
                              New front tire or new front rim (got a front end shimmy i'm trying to track down, already triple checked the triple tree hardware/ replaced the bearings etc)
                              new bars
                              Then painting everything (still stockpiling paint and airbrush supplies)

                              Then it will be on to my next project, my 79 yamaha xs650
                              The road star is my daily driver, so working on it can be sporadic, I'm hoping to get it done by the end of march

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                              • #16
                                Sounds like a lot of work but I am sure the end result will justify the hard work. Keep us informed of you progress via pictures. Ride safe, be safe.

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