RidersDiscount.com AMA SuperSport Suzuki GSX-R600 Build

[ridein]

:)Good luck,Looks sweeeeeeet....

[RidersDiscount]

Riders Discount GSX-R600 AMA SuperSport Build - Day 1

With a brand new bike and a bench full of parts, we were ready to get started. The first order of business was to tear the showroom fresh Suzuki down. This meant draining all the fluids - a job which was aided by a Mityvac.

We obviously weren’t going to go racing with the stock exhaust, so that was the next thing to go.

A new Yoshimura system was waiting nearby to take its place.

When removing the stock chain, we find it’s easiest and fastest to grind down the rivet.

This makes it very easy to finish the job with a flathead screwdriver.

Next order of business was to get the tank and airbox out.

We removed the OEM forks, but they would be going back on, as SuperSport regulations require their use. They do allow for modified internals, however.

A new set of Vortex adjustable rearsets was the only thing that we actually added to the bike on the first day.

We were left with a very different bike by the end of day 1.

[Helmutt]

So do you wrench for the team AND work in sales? Just curious.

Looks like a fun job for sure

[RidersDiscount]

So do you wrench for the team AND work in sales? Just curious.

Looks like a fun job for sure

I am not the hired hand to do these builds although I help when I can. We have an AMA tech on staff that does these builds for us.

Also, this bike is already done but we're doing a post-build thread highlighting the good bits.

We'll hopefully have another real-time build coming soon

[RidersDiscount]

The first order of business on day 2 was to service all the bearings - starting with the steering head.

With plenty of grease on the ball bearing, it was immediately reinstalled.

Next, it was the swingarm's turn to hit the workbench and get a full going over.

These bikes are obviously put under a much higher level of stress than most, so all the bearings were pulled, checked and serviced, despite being brand new.

Supersport only allows for limited modifications, and because of this, little details can make a difference. One such detail was shaving down the chain guide in order to lessen the chance of the chain rubbing.

With those tasks finished, it was time for the swingarm to go back on.

The forks had been reworked with Traxxion internals and were ready to be installed as well.

[4DAIVI PAI2K5]

Moar

[RidersDiscount]

Stripping the street parts off of the bike left a lot of empty plugs on the OEM wiring harness, so it was time for the Yoshimura full race harness to take its place. This didn’t only clean up the wiring though, it also allowed us to hook up the Yoshimura EM Pro ECU.

Good things come in shiny boxes.

Even the pros need to check the instructions from time to time.

A new brain, courtesy of Yoshimura.

Next up was a set of Renthal Clip-ons and a Motion Pro Revolver Quick Turn throttle.

The Motion Pro Revolver throttle makes it very easy to adjust the twist rate by switching the throttle reel to any of the four that come with the kit.

A Yoshimura R77 titanium exhaust was then installed to take the place of the OEM system, starting with the exhaust spigots.

Yoshimura vs. OEM headers. We know which set we prefer. What about you?

The last part we installed on day 2 was a Motoholders fairing stay with an AiM MXL dash. The dash was on hand in case we decided to develop the bike for DSB, and was not used in SuperSport.

Here’s how the bike sat at the end of day 2.

[RidersDiscount]

Day 3 started with a few more additions, including some electronics from Bazzaz. We already Yoshimura EM Pro Race ECU installed at this point, which provides complete engine management. The Bazzaz Z-FI and Z-AFM made it very easy to get a solid baseline map that we could start tuning from.

A set of adjustable CRG RC2 levers were added at this point...

...as well as the Yoshimura carbon fiber canister to complete the exhaust system.

SuperSport requires the use of the OEM calipers, so it was time for the stock Brembos to go back on.

Before they did, one small alteration was made. A beveled edge was added to the brake pads. This little detail can make putting a wheel back on much easier if you’re in a hurry.

It was then time to drill all the necessary pieces for safety wire.

The bodywork had been sent off to be painted by Andrew Swenson at the start of the build, and the first piece was now ready to be test fitted.

Let’s just say there was a little bit of metal flake in the paint. There was no mistaking it when it was in full light.

With the front end coming together, the brakes got their fluid and were bled. Just like at the beginning, a Mity-Vac helps keep things clean and simple.

It was starting to look less like an assortment of parts, and more like a bike by the end of day 3.

[jdonn]

Looks awesome man! Thanks for sharing!

[RidersDiscount]

[RidersDiscount]

By the fourth day of the build, most of the work was done and just a few tasks remained before it was ready to hit the track.

The first was to get the rear wheel was back on and the chain adjusted.

Our fuel tank also needed a cap, so we went with an Accossato piece.

A set of Sharkskinz bodywork had been sent off for a custom paintjob by Andrew Swenson Design, and it was finally time to see it on the bike.

With the bike fully assembled, it was time for a shakedown. We enlisted the help of AMA Pro, Joey Pascarella, packed up the Suzuki, the Riders Discount Triumph 675, and headed out to Gingerman Raceway. Joey was fresh off of his win at the 2012 Daytona 200 and wasn’t shy about putting the bike through its paces.