One of the most attractive things about the Suzuki VX800 is the ease with which it can be modified. I have made several changes to my 1990 model. A few of them are documented here.
Much of my riding is done as an official in bicycle races. Between riding to and from races all over the Northeast and riding in the races themselves I average 10-12,000 miles a year. Visibility is a key element in performing my duties in these races. For safety reasons it is important that both the racers and the non-racing public see or hear my motorcycle when necessary. You will see that many of my mods are designed to accomplish these goals.
One of my early mods was to replace the feeble VX horn with a pair of Fiamm Highway Blaster Hi/Lo horns. Since they would not fit on the standard horn mount, I stole a page from Glen Farney's book and mounted them under the read body plastic. They are attached to the rear bolts on the rear footpeg bracket. Using this mounting method the horns are semi-hidden just in front of the rear shocks. A standard 12v relay controls the horns as shown on this wiring diagram (Click to view) by an unknown hero to whom I am very grateful.
Another early mod was to install Saeng/TA Nightcutter fog lights. I chose the fog lenses because I was more interested in being visible than increasing road illumination. They are connected via a standard 12v relay to a fused connection to the battery and to a Galls™ Multi-Pattern Flasher. (Click to see the flashing pattern on a police car). I've since removed the windscreen border as it provided no noticeable benefit on the National Cycle Street EX windscreen.
|
|
|
This system is controlled by a switchbox mounted on the '92 VX-style upper handlebar clamp. I made this switch box from a small Radio Shack project box (3x2x1) and 3 push button switches mounted on the long side facing me. That way water runs off the unit. In three years and many rainy miles it continues to work. The left switch controls my home-made 4-way flashers; the center, the Galls flasher; and the right, the fog lights. Because of the Gall's circuitry the fog light switch overrides the flasher switch. The fog light switch runs through a relay identical to the one used for the horns with appropriate modifications so that they are controlled by the switchbox.
After spending $50 for a Kriss 4-way flasher that failed within a year (My friend, Hank, had 2 fail in the same period) I searched the web for an inexpensive solution. A member of the VX80 List Serve directed me to Chet Walter's Four Ways for Five Bucks web site. After reviewing Chet's schematic and researching his parts, I decided to modify it slightly and use a DPDT relay instead of a DPDT switch. That way I could hide the whole unit under my seat and control it from my bar-mounted switchbox. Finding a cheap DPDT relay was not easy but once again the selection at Radio Shack prevailed. I found a 12vdc DPDT relay rated @ 10 amps for $8 (part # 275-218). I also picked up a package of small spade connectors and some heat shrink tubing. I found the flasher relay at Pep Boys for $4.00.
I followed Chet's wiring diagram for the most part. However since the default (Power-off) switches the two bottom connectors on, I used heat shrink to isolate them from anything else. They serve no purpose in this application.
As with all other relays in my systems, I pick up the control voltage by splicing into the tail light circuit. Since the relay's power requirement is quite low, it is not a burden on the taillight circuit and I can now control power on/off using the key. Power is now available when the bike is running and by switching the key to the 'Park" position I can have my 4-ways operate with the key out of the ignition if necessary.
I've been very pleased with this system as is Hank with the one I installed on his VFR. Total install time was about 1 hour.
I also replaced the exhaust system. The original system had developed the "broken-inner-pipe" syndrome. After screwing it tight with sheet metal screws twice I decided to replace it with a PipeMasters stainless steel system.
 |
 |
 |
While the replacement process was not painless, the folks at Pipemasters were excellent in helping to resolve the niggling little bits that weren't perfect the first time around. When finished I found them beautiful to look at and their sound ... well ... glorious! (Click to hear them)
BUT!
As much as I personally loved the sound of the pure Pipemaster system, the bicycle racers and my fellow officials did not. There is a time and a place to be heard in a bicycle race and it's not all the time and everywhere! Another modification was required
I happened to be visiting Andy (of VX List fame) on the west coast and asked if he had any ideas for an inexpensive solution to my problem. He asked if $25 was too much to spend. Needless to say I was more than a little bit curious.
The solution was to take advantage of a peculiarity of Ducati Monster owners. It seems that many of them elect to replace their perfectly fine OEM exhaust canisters with much more macho sounding units. In the doing the dealers are left with perfectly good canisters for which there is no market.
Because I'm an impatient type and there are no Ducati dealers near me in North Central Pennsylvania, I found a pair offered on eBay at an unreasonable price ($150). I let the owner know that if his auction failed I'd pay him $50 for them. He countered at $60 + shipping. We had a deal.
A few days later they were in my soon-to-be grimey hands. I removed my beautiful Pipemaster cans and, using some flexible exhaust piping I was able to rig a makeshift proof-of-concept. (See pics here.) My local pipe bender did a serviceable job of bending the headers so they worked with the new cans. In the process I lost the on-the-road use of my centerstand and an extension to the kickstand had to made so I could reach it. The centerstand can be reattached in a few moments when needed for tire and oil changes.
As can be seen, the end result is less than perfect visually but I am very pleased with both the sound and the performance. Once again my VX is welcome at bicycle races and it will now freely rev past the red line if I don't pay attention. Peter Gray of Pipemasters quoted US$225 for a set of headers that will more carefully match the bend of the OEM pipes. That should improve the appearance significantly. I'll probably try a set in 2002.