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ChairMachineGun
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Posts: 35
Joined: Apr 2012
From: Detroit, MI
Bike: S50
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Posted: Apr 25, 2012 10:36 AM (Msg. 1 of 116)
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So I just picked up a 2007 Boulevard S50 800 w/1,2XX miles. I think it looks a little homo,
so I decided to start building (or un-building in all honesty) it into a street bobber.
I need info on seats, and fenders, or fender cutting, as well as exhaust,
jetting, and re-tuning. Thanks. I will update pics as I progress.
Day I: No Homo
^This is the day I bought the bike. Bone Stock. Looks a little girly for my taste.
So I decided to strip off the gaudy tool box to start. I'm new to this so I started small.
Day II: Louder is better
So today I decided to remove the baffles from my exhaust in hopes of gaining a much louder and throatier sound and feel. To do this I started by taking my harbor freight slide hammer (seen above) and removed the fitting on the end leaving just the slide rail with threads at one end, and the hammer, and handle. Now if you are as lucky as I was... your exhaust baffle is almost an exact fit for the threaded slide of the slide hammer. This made threading the slide hammer directly into the exhaust baffle pretty easy. I screwed it in about 6-8 good turns which secured the slide hammer firmly inside the baffle. Then I simply "slide-hammered" the baffle out. It came out in about 3-4 good slams. The nice thing was the baffle came out un-scathed so I can re-use it if I ever chose to. I did the same for the other side baffle. As most of you know this much improved the sound of my bike. However... Its not enough. I am going to do something more... dramatic.
Day III: The Tear Down
So I started by stripping the front fender, driver's mirror, side covers, seat, rear chrome support bars, taillight, license plate mount, stator, rear fender, exhaust mufflers, and battery box. That's it for tonight. Tomorrow I plan to design the solid rear suspension, and a new shorter battery box with a smaller battery capable of the same cranking amps. Ill update more soon. Did I mention I stripped the gaudy front and rear turn signals as well? Gone.
Below are a few pics of what I am going for, minus the handle bars. I need info on what seat was used, and fender, ect. I know the owner is a member so any help would be awesome!!
 Edited by ChairMachineGun on Apr 25, 2012 at 10:42 AM
Detroit Police.
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BRONX INTRUDER
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Posts: 5679
Joined: May 2010
From: Bronx, NY
Bike: VS1400
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Posted: Apr 25, 2012 11:18 AM (Msg. 2 of 116)
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"No Homo" Is too funny!
Anyways, Nice job. Practically new. I see your pipes are turning blue already though. Might need some tuning there buddy but you're already going to have to get that done with your mods. haha.
That fender is stock, just cut and rolled If I'm not mistaken. Or it's just cut. But it's stocker modded.
Good luck and Welcome aboard! 
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HCDawg
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Joined: Mar 2012
From: Brampton, ON
Bike: VS700/750
On a Steel Horse I Ride
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Posted: Apr 25, 2012 12:03 PM (Msg. 3 of 116)
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Is the seat for sale? Can I buy it? I don't think it looks homo 
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jtvs800
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From: Wellington, AL
Bike: VS800
boo-yah!
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Posted: Apr 25, 2012 12:44 PM (Msg. 4 of 116)
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gobaktosleep is from my neck of the woods!thats a stock seat off an 80s model intruder.the rear fender is cut and rolled.he did about 4 or 5 bikes like the one abouve,thats just intruders.he also did other bikes too!the one on the right in the pic is a yamaha virago...
my sled!!
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ChairMachineGun
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Posts: 35
Joined: Apr 2012
From: Detroit, MI
Bike: S50
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Posted: Apr 25, 2012 01:06 PM (Msg. 5 of 116)
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Quote:HCDawg wrote:
Is the seat for sale? Can I buy it? I don't think it looks homo 
Na, I am not selling any of the original parts just yet in case I have to return it to stock.
Quote:jtvs800 wrote:
gobaktosleep is from my neck of the woods!thats a stock seat off an 80s model intruder.the rear fender is cut and rolled.he did about 4 or 5 bikes like the one abouve,thats just intruders.he also did other bikes too!the one on the right in the pic is a yamaha virago... Well I need a fender. I dont want to cut my original. What should I buy to make it look the same? I am brand new to all this but I am diving in head first to get this done.
Detroit Police.
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Tilos
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Joined: Dec 2010
From: Kuna, ID
Bike: S50
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Posted: Apr 25, 2012 01:48 PM (Msg. 6 of 116)
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Homo...really  .
Just keep cutting and hacking
And I'll keep ridin' my homo/girly bike
Tilos Edited by Tilos on Apr 25, 2012 at 01:49 PM
ANY MANUAL IS BETTER THAN NONE
750/800: https://dl.dropbox.com/u/96125666/Suzuki_Vs_700_800_Intruder_Service_Manual_Eng.pdf
http://www.mediafire.com/view/?6iymtvtm13j83u1
Tilos
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BRONX INTRUDER
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From: Bronx, NY
Bike: VS1400
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Posted: Apr 25, 2012 01:54 PM (Msg. 7 of 116)
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Another rear fender that you can cut.
An old 80's Intruder front seat.
Exhaust turn out tips from an auto-parts store if you going for that same thing.
Exhaust wrap?
He doesn't have much going on there. You're almost done. lol.
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BRONX INTRUDER
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Joined: May 2010
From: Bronx, NY
Bike: VS1400
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Posted: Apr 25, 2012 01:54 PM (Msg. 8 of 116)
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Quote:Tilos wrote:
Homo...really  .
Just keep cutting and hacking
And I'll keep ridin' my homo/girly bike
Tilos
Edited by Tilos on Apr 25, 2012 at 01:49 PM

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Vegas Larry
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From: Las Vegas, NV
Bike: VS800
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Posted: Apr 25, 2012 03:46 PM (Msg. 9 of 116)
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Quote:Tilos wrote:
Homo...really  .
Just keep cutting and hacking
And I'll keep ridin' my homo/girly bike
Tilos
Edited by Tilos on Apr 25, 2012 at 01:49 PM
I knew you would jump in on this "white" bike thread!! 
I prefer the second one best...
VS800 1992 - 2009 Factory Workshop Service Repair Manual
VS700_VS750_VS800_1986-2008_Service Manual
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ChairMachineGun
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Posts: 35
Joined: Apr 2012
From: Detroit, MI
Bike: S50
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Posted: Apr 25, 2012 04:17 PM (Msg. 10 of 116)
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Quote:BRONX INTRUDER wrote:
Another rear fender that you can cut.
An old 80's Intruder front seat.
Exhaust turn out tips from an auto-parts store if you going for that same thing.
Exhaust wrap?
He doesn't have much going on there. You're almost done. lol. Thanks bud!!
Now I just need to find those parts. eBay is lacking in the 80's Intruder Seats Department.
Who knows how to jet a bike with the exhaust mods, and filters on the carbs? Tuning tips too.
Detroit Police.
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BRONX INTRUDER
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Posts: 5679
Joined: May 2010
From: Bronx, NY
Bike: VS1400
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Posted: Apr 25, 2012 05:50 PM (Msg. 11 of 116)
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Quote:ChairMachineGun wrote:
Thanks bud!!
Now I just need to find those parts. eBay is lacking in the 80's Intruder Seats Department.
Who knows how to jet a bike with the exhaust mods, and filters on the carbs? Tuning tips too.
Seat
I'm sure jetting tips will come in sooner or later. lol.
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navigator

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From: Frostbite Falls, NY
Bike: S50
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Posted: Apr 25, 2012 06:31 PM (Msg. 12 of 116)
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Vegas Larry
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From: Las Vegas, NV
Bike: VS800
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Posted: Apr 25, 2012 07:24 PM (Msg. 13 of 116)
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If you want to do exhaust and intake (filters) I suggest you talk to Cruiser Magic 2 .
I have met them personally and they are good, honest people.
Their Stage Two jet kit comes with needles, jets and K&N filters.
They also have a very popular ehaust system, the CM 2 I believe it is called.
I prefer the second one best...
VS800 1992 - 2009 Factory Workshop Service Repair Manual
VS700_VS750_VS800_1986-2008_Service Manual
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ChairMachineGun
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Posts: 35
Joined: Apr 2012
From: Detroit, MI
Bike: S50
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Posted: Apr 26, 2012 08:48 AM (Msg. 14 of 116)
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Day IV: Solid V.S. Shocks
Thanks for all the help so far. Hopefully I can have a seat ordered by the weekend.
As for jetting. There is a company called 6-Sigma that custom tailors jet kits to your bike/mods.
I think I may buy it from them. Stage 1-5 kits available. No filters tho.. Kit is only $49.00
Kits Includes:
Main Jets
Pilot Jets
Needle Adjusters
Slide Spring Modification
Nylon Spacers
Drill Bits for
Slide Hole Modification
Idle Mixture Modification
Bike Specs
Carb Schematic
Carb Synchronizer Tool (how to build for $5)
Step by step instructions with photos customized to your bike.
Here is what I did last night in the 45 minutes I had before the wifey came home:
1: Removed the gas tank to access the carb inlets for filter measurements/clearances.
2: Cut a 12" piece of 1"x2" and drilled two pilot holes 10" on center to gauge 10" shock height.
3: Install the template. I think I can get away with 10" solids, or 11" shocks. I'm going to try both.
Edited by ChairMachineGun on Apr 26, 2012 at 08:50 AMEdited by ChairMachineGun on Apr 27, 2012 at 07:44 AM
Detroit Police.
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HCDawg
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From: Brampton, ON
Bike: VS700/750
On a Steel Horse I Ride
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Posted: Apr 26, 2012 09:20 AM (Msg. 15 of 116)
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I think you should keep the wood
Tilos...where did you buy your risers and what width are your handlebars?
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Tilos
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Posts: 2171
Joined: Dec 2010
From: Kuna, ID
Bike: S50
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Posted: Apr 26, 2012 09:24 AM (Msg. 16 of 116)
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You might want to consider using the front/bottom half of the fender strut as it supports and adds strength the upper shock mount.
Without it, that upper mount will get a twisting force from the road. thru the strut.
just sayin'
Tilos
What stain are you going to use on those struts  .
ANY MANUAL IS BETTER THAN NONE
750/800: https://dl.dropbox.com/u/96125666/Suzuki_Vs_700_800_Intruder_Service_Manual_Eng.pdf
http://www.mediafire.com/view/?6iymtvtm13j83u1
Tilos
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Tilos
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Joined: Dec 2010
From: Kuna, ID
Bike: S50
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Posted: Apr 26, 2012 09:29 AM (Msg. 17 of 116)
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HC:
The risers are stock form another year, measure 4 1/2", and are mounted in reverse.
The bars are from J&P, cut to stock length, but have about half the bend angle of the stock bars.
Too Homo...what do you think?
Tilos
sorry for what I typed right there Edited by Tilos on Apr 26, 2012 at 09:34 AM
ANY MANUAL IS BETTER THAN NONE
750/800: https://dl.dropbox.com/u/96125666/Suzuki_Vs_700_800_Intruder_Service_Manual_Eng.pdf
http://www.mediafire.com/view/?6iymtvtm13j83u1
Tilos
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ChairMachineGun
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From: Detroit, MI
Bike: S50
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Posted: Apr 26, 2012 09:37 AM (Msg. 18 of 116)
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Well currently... those are the stock 2007 Risers and Handle Bars from Suzuki.
As for the Rear strut brace? Idk what that is exactly? I am still very much a greenhorn.
As for the stain... I am thinking Jacobean or Walnut Edited by ChairMachineGun on Apr 26, 2012 at 09:45 AM
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BRONX INTRUDER
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Joined: May 2010
From: Bronx, NY
Bike: VS1400
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Posted: Apr 26, 2012 09:44 AM (Msg. 19 of 116)
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Quote:ChairMachineGun wrote:
Well currently... those are the stock 2007 Risers and Handle Bars from Suzuki.
As for the Rear strut brace? Idk what that is exactly? I am still very much a greenhorn.
The chrome Rails that you took off. You can cut the rear half of them off just after they attach to that wooden strut mounting point. Keep the front part on so it keeps that mounting point strong.
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ChairMachineGun
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Posts: 35
Joined: Apr 2012
From: Detroit, MI
Bike: S50
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Posted: Apr 26, 2012 09:49 AM (Msg. 20 of 116)
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I'll consider that. However it doesn't look like anyone else has used those pieces on their bobbers? I also dont want to modify any of the factory parts if possible in case I decide to return to stock.
Day V: Online Shopping
So last night I measured my Carb inlets. 50mm each. Then hopped on the computer and picked up these bad boys on eBay. (Below) Only set me back $18 shipped for both!!
While I was browsing.. I also picked up a radiator grill. I like it. What do you think?
Edited by ChairMachineGun on Apr 27, 2012 at 08:08 AM
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