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2003 Roadstar 1600

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  • highvoltage
    replied
    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.

    Leave a comment:


  • Overkill jones
    replied
    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

    Leave a comment:


  • Overkill jones
    replied
    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

    Leave a comment:


  • Overkill jones
    replied
    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!

    Leave a comment:


  • Overkill jones
    replied
    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

    Leave a comment:


  • Overkill jones
    replied
    https://www.youtube.com/watch?v=_u5QSIrgjjU

    Leave a comment:


  • Overkill jones
    replied

    Leave a comment:


  • Overkill jones
    replied
    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

    Leave a comment:


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

    Leave a comment:


  • Overkill jones
    replied
    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 new 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

    Leave a comment:


  • Overkill jones
    replied
    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

    Leave a comment:


  • Overkill jones
    replied
    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

    Leave a comment:


  • SKWEARpeg
    replied
    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.

    Leave a comment:


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

    Leave a comment:


  • Shores
    replied
    Ouch!....if you ever get tossed over the handlebars and impaled!

    Leave a comment:


  • Overkill jones
    started a topic 2003 Roadstar 1600

    2003 Roadstar 1600

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

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