{"id":47558,"date":"2018-06-24T20:37:09","date_gmt":"2018-06-24T11:37:09","guid":{"rendered":"https:\/\/www.decoboco.info\/en\/?p=47558"},"modified":"2026-09-24T13:45:06","modified_gmt":"2026-09-24T04:45:06","slug":"gsxr1100l-main-harness-replacement-sunstar-disk-kit-4","status":"publish","type":"post","link":"https:\/\/www.decoboco.info\/en\/20180624\/everyday-events\/gsxr1100l-main-harness-replacement-sunstar-disk-kit-4","title":{"rendered":"\u2461GSXR1100L Main Harness Replacement Sunstar Disk KIT and More"},"content":{"rendered":"

\"\" We’ve settled on a plan that isn’t a hassle, so here’s the GSX400S Impulse fairing installation.<\/p>\n

<\/p>\n

\"\"
\nIt was already installed, but this time we’re cleaning it up nicely due to the damage.
\nThings I pay attention to when installing a bikini fairing on a naked bike.<\/p>\n

\u2022 Don’t obstruct front fork removal and installation or front-end maintenance.
\n\u2022 Fairing removal and installation should be easy.
\n\u2022 The fairing should be removable so the bike can still be used as a naked bike.
\n\u2022 The structure should be simple so it recovers quickly from crashes or accidents.
\n\u2022 Vertical and horizontal headlight beam adjustment should be included.<\/p>\n

That’s about it. I think a spec that makes everyone happy helps down the road.<\/p>\n

So here we go…<\/p>\n

\"\"
\nFirst, it’s best to avoid mounting the headlight and lamp bracket on the fork as much as possible.
\nFork removal and installation and front-end maintenance become difficult.<\/p>\n

It’s the typical Suzuki push-fit type. We’ll repurpose one from a Goose 350.
\nGoose 350 = 50\u03c6 straight tube
\nGSXR1100L = 52-56\u03c6
\nSo it won’t work at all.<\/p>\n

\"\"
\nBeing frugal, I’ve collected various backup rings, so I’ll use a suitable diameter as material.<\/p>\n

\"\"
\nI cut it in one place, then use the lathe chuck to expand it 4mm beyond the standard dimension.
\nThen I insert a perfectly fitting inner diameter collar, chuck it, and weld it four times to finish.<\/p>\n

\"\"
\nCutting and fixing the rubber is sufficient.<\/p>\n

\"\"
\nI paint it a little with a lifetime supply of touch-up pens.
\nNow the bracket is fixed to the fork.<\/p>\n

\"\"
\nSince it’s a bar-handle bike, an unused boss will contact it, so I cut it and smooth it out.<\/p>\n

\"\" \"\"
\nEveryone, when choosing a headlight…
\n\u2022 Domestic brand.
\n\u2022 Has left-right adjustment.
\n\u2022 Rear case is plastic.<\/p>\n

\u3007 Cheap Chinese multi-reflector lights have poor plating inside the lens and lower light output than domestic brands.
\n\u3007 Headlights on inspection-certified vehicles should have vertical and horizontal beam adjustment as a matter of courtesy.
\n\u3007 Plastic cases make it harder to short-circuit with tightly packed wiring. Lightweight.<\/p>\n

If you know from the start, you won’t have trouble with light output or adjustment at inspection, and the chance of wiring trouble from shorts drops significantly, plus it’s lightweight.<\/p>\n

\"\"
\nFor now, I’m making a mock-up on just one side to check the position.<\/p>\n

\u2022 OK even if the fork goes through full stroke
\n\u2022 OK to ride as a naked bike
\n\u2022 OK even if we go radial master later
\n\u2022 No contact with any parts!<\/p>\n

With these rules set, the process of elimination shows there’s only one place it can go. Then I look from the front and sides and think, what if this were mine? and proceed.<\/p>\n

 <\/p>\n

\"\"
\n5052\/T-5mm aluminum offers lots of recovery options.
\nQuick drilling and cutting. It’s not finished yet, so there are scratches and dirt.<\/p>\n

\"\" \"\"
\nThe light is still mine. I really wanted to bend it, but it fits perfectly.
\nIf it’s long, bending it looks more three-dimensional and cool, but that’s how it is.<\/p>\n

This is as far back and as low as it can go.<\/p>\n

\"\"
\nWe’re repurposing a fairing stay from an Impulse 400.
\nGenerally speaking, I…
\n\u2022 Can make one-off parts, but it’s a hassle = expensive
\n\u2022 In case of emergency, recovery is difficult, time-consuming, and expensive<\/p>\n

I think you should choose based on what’s right for the job and your budget and mood. Sometimes you want to go light with aluminum or titanium, after all.<\/p>\n

\"\"
\nThe width is off by 5mm, so I’ll weld a collar to the fairing stay side.
\nIn case we need to remove it later, a design that prevents things from falling apart might come in handy.<\/p>\n

\"\" \"\"
\nJust like stock. Nobody notices, it’s completely understated…<\/p>\n

\"\" \"\"
\nThis fairing looks cool with a slight chin tuck.
\nNext is vertical beam adjustment and vertical positioning.<\/p>\n

The upper fastener is nice, right? I’ll do that.<\/p>\n","protected":false},"excerpt":{"rendered":"

We’ve settled on a plan that isn’t a hassle, so here’s the GSX400S Impulse fairing installation.<\/p>\n","protected":false},"author":2,"featured_media":47539,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"pochipp_cv_data":"","swell_btn_cv_data":"","footnotes":""},"categories":[1924],"tags":[151,169,135],"class_list":["post-47558","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-everyday-events","tag-gsxr","tag-main-harness-replacement","tag-sunstar-kit"],"_links":{"self":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/47558","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=47558"}],"version-history":[{"count":0,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/47558\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media\/47539"}],"wp:attachment":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media?parent=47558"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/categories?post=47558"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/tags?post=47558"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}