{"id":45136,"date":"2019-02-18T20:58:41","date_gmt":"2019-02-18T11:58:41","guid":{"rendered":"https:\/\/www.decoboco.info\/en\/?p=45136"},"modified":"2026-09-24T13:45:17","modified_gmt":"2026-09-24T04:45:17","slug":"gsxr1100j-gs1000r-hb-replica-generator-swap-rear-caliper","status":"publish","type":"post","link":"https:\/\/www.decoboco.info\/en\/20190218\/everyday-events\/gsxr1100j-gs1000r-hb-replica-generator-swap-rear-caliper","title":{"rendered":"GSXR1100J (GS1000R-style HB replica) generator replacement, rear caliper replacement, side stand shortening, Watanabe SP2 inspection, tank quick-release mod VR2"},"content":{"rendered":"
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GSXR1100J (GS1000R-style HB replica) generator replacement, rear caliper replacement, side stand shortening, Watanabe SP2 inspection, tank quick-release mod VR2 is what we’re working on. <\/figcaption><\/figure>\n\n\n\n\n\n\n\n
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First, we’re swapping the generator for a newer one to make it compatible with MF and lithium batteries. The aluminum was all powdery, so I gave it a light polish. <\/figcaption><\/figure>\n\n\n\n
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The customer wanted the cover blacked up, so I sanded the surface and prepped it. <\/figcaption><\/figure>\n\n\n\n
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That’s how it turned out. It’s nice to see each piece getting cleaned up one by one. Lately we’ve been able to do things like gun coating, so our finishing options have expanded, turnaround times are shorter, and distribution and outsourcing costs are down\u2014which means profit margins are up, maybe?

Sure, we could outsource everything, but…
\u2022 It takes longer
\u2022 Shipping and distribution costs go up
\u2022 It’s hard to communicate the fine details and nuances; you need detailed instructions.
\u2022 Of course there’s a middleman cost, so the final price goes up
\u2022 If something goes wrong, it’s hard to place blame
In the end, someone’s going to cry… I wish I hadn’t gotten in the middle… that’s the classic outsourcing story.
Someone said the other day… “Bad taste is congenital.”
“Gulp!” I wonder if I’m okay…

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The generator gear’s outer diameter (tooth count) is different, so we’re reusing it. (If you just swap it in as-is, it won’t work\u2014it’s all about measuring, measuring.)
By the way:
1100G-N 28T 22730-06B02 (part number has changed)\u2014all GSXR models
Bandit 26T 22730-27A05\u2014all Bandit models, GS1200SS, Inazuma\u2014latest generation?
GSF1200 22730-27A03\u2014I’ll check the tooth count…
that’s it.

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I was impressed that we had this connector in stock. I think it’s good manners to install it to OEM standards so that whoever services it next, no matter where or when, will understand what was done. <\/figcaption><\/figure>\n\n\n\n
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There’s a subtle misfire issue, so we’re sending the Watanabe unit and coil in for inspection. If you suspect something’s wrong, it’s better to get it checked.
We made a bracket for the Watanabe coil when we replaced the harness last time, so it’s easy to remove and install.

Basically, if you use rear-side nut fastening on aftermarket parts, you increase the tools and labor needed. Just bolting it on is something anyone can do. But to go beyond that takes an extra step. <\/em>
If the customer’s going to keep coming back, I figure making it convenient and clean will pay off in the end\u2014and it really does! <\/figcaption><\/figure>\n\n\n\n
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Checking the numbers. The Watanabe unit is positioned where it’s easy to adjust and remove, so it went smoothly!

I’d rather not fix the unit to the frame with double-sided tape if possible\u2014it’s a pain to remove and clean up.
Any aftermarket part comes with instructions that anyone can follow. But the reality is they don’t account for failure, removal, or maintenance workflow. If you don’t think about it from the installer’s perspective, you won’t get that OEM-quality finish. It’s surprisingly deep.


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The bike was standing too tall and the customer was nervous, so we’re shortening the side stand.
The angle shown is my own reference, so it’s rough. But if you don’t know the standard before you modify, the result can end up being just a guess.
When you’re cutting and welding, it’s fine to check against your own standard first, then proceed. That way when you explain the modification to the customer afterward, you’ll have more credibility. <\/figcaption><\/figure>\n\n\n\n
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The sole was hard to reuse as-is, so we made a new one. Then we gradually cut and adjust.
When I make a side stand, I always use SUS304, so <\/em> steel and aluminum machine really nicely\u2014super easy.

I thought about stocking steel tubing too, but then people wouldn’t know what kind of shop we are, so I’ll skip it…


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On the stand side, I lightly beveled the edge, filled it, and welded to maximize contact area. Even if it peels, it’s not a problem, but we’re doing it right and safe anyway. <\/figcaption><\/figure>\n\n\n\n
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The stand assist\u2014or whatever you call that bent rod that pops the stand out.
I don’t like the kind that just shoots out hard, so I don’t do that.

I’ve seen imported vintage bikes where bolts are just carelessly welded on… you either don’t care or figure as long as it’s there, it’s fine. But as someone doing the work, I want to care a little.

And ease of deployment is really important. The rider’s burden should be as light as possible. A stiff or heavy stand just makes you go “ugh!” <\/figcaption><\/figure>\n\n\n\n
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So this one’s getting replaced. With this… they want me to deploy it… I’m not sure about that. <\/figcaption><\/figure>\n\n\n\n
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The paint is black with gun coating. It should be pretty tough and rust-resistant. You can wash it hard and not worry. It’ll stay looking good for a long time.
Basically, I keep the sole flat on the ground. I see some aftermarket or modified stands where the sole is lifted, and I think that’s a bit of a shame.
If you look closely at an aftermarket or modified stand sole, you’ll go “oh!” and notice it. <\/figcaption><\/figure>\n\n\n\n
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It doesn’t interfere with shifting, you get good lean angle, and it’s easy to deploy even with boots on. A side stand that doesn’t frustrate you adds one more reason to enjoy riding.
*Decoboco is not a fabrication shop, so we basically don’t take on this kind of work. You’d be better off contacting a custom shop or metal fabricator. <\/figcaption><\/figure>\n\n\n\n
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The Watanabe unit came back as a loss… poor thing.
I gun-coated the caliper the old man is going to use black.
The GSXR1100 is basically floating, so this caliper can’t be used as-is. Of course we set it up so it works, but there’s a reason we’re not showing pictures. <\/figcaption><\/figure>\n\n\n\n
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The customer likes carburettor tuning and gets into it, so we’d made the tank quick-release, but it was originally rigid. It was rattling, so they asked if we could add a damper.
I thought about it… (which rubber to use)… and came up with this design. <\/figcaption><\/figure>\n\n\n\n
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I hate pop rivets (rivet nuts). This one’s OEM so we have to use it, but I can’t really recommend them for frame use. They spin easily, and when you replace them, they get stuck inside the frame.
If you don’t care, fine, but on my own bike I’d hate it.

Anyway, with this rivet nut, the head pops out, so we countersink it to keep it from breaking. <\/figcaption><\/figure>\n\n\n\n
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I counterbored the frame side so the base sits flush. (Sorry for the chatter marks on the surface.) <\/figcaption><\/figure>\n\n\n\n
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19mm across flats, finished with a mill, and threaded stud installation. <\/figcaption><\/figure>\n\n\n\n
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Quick-release with damper, removable with a cotter pin. We haven’t found the perfect damper yet, so this is a beta test.
Eventually, if we extend the lower plate and also extend the tank side, wouldn’t it be easier to remove? they said…
“Oh!” I never thought of that… the customer’s wisdom is amazing!

This time there’s a lot of small custom work, but basically we don’t do fabrication-only jobs.
Repeat customers or people we think we’ll have a long relationship with are totally fine.
We have our own schedule, so please understand.

That’s all for this time. <\/figcaption><\/figure>\n\n\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":2,"featured_media":45111,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"pochipp_cv_data":"","swell_btn_cv_data":"","footnotes":""},"categories":[1924],"tags":[],"class_list":["post-45136","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-everyday-events"],"_links":{"self":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/45136","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/comments?post=45136"}],"version-history":[{"count":0,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/45136\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media\/45111"}],"wp:attachment":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media?parent=45136"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/categories?post=45136"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/tags?post=45136"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}