View Full Version : GSX 600F SII Build

Marlboro Man
10-05-2016, 01:10 AM
I've been looking on this site for about a year, and I bought a set of Shredder II plans before the ubuildit site went down. I wanted something that my kids and I could build together and ride together, similar to some other posts I have seen. I decided to post on here, as I have found tons of great information on the site, and from what I can see people willing to share, as I may need help later on down the road.

I've taken some of my modifications to the plans from others on here in the shredder group, so thanks.

A far as my build, here goes.............

I was able to find a used 96 Suzuki Katana GSX600F that had an engine with broken valve and a seized piston. Basically, I gutted that engine to use to mock up purposes. I have a complete engine, that the seller sold me as part of the deal, for when I get ready to finally install. The seller stated it ran when he bought the engine, but never put it on the bike. I'm going on his word. So, for now, I have 2 engines, one is a shell now and the other supposedly runs. That will be later down the road though.

Ive started on the frame, sides, and front end.

Here is the stripped down engine


The complete engine



What Ive got together after about 3 weeks of work



No tube bender so i had to cut and fit the angles, probably not as structurally sound as the bend, but im going to add in some bracing and gussets to stiffen the cage up.


So this is my progress so far. Ill keep posting and updating as I get further along.

10-05-2016, 02:03 AM
Welcome MM.

Rhode Island, don't hear that too much on here. Do you have a spot to ride?

It looks like your using a Hobart mig welder? Whch one do you have? It also looks like your using flux core wire? If you get a chance you'd be very happy if you could set your mig up with a small gas bottle and solid wire. Its very easy and your welds (and cleaning up) will be much nicer.

Your off to a good start.

Ive never built this buggy and don't know much about them, but Ive followed the other builds on here. One thing I don't understand after seeing it again is why the lower/floor tubes are two piece? Is there a reason?

10-05-2016, 02:17 AM
Welcome to minibuggy. Great first post! I have a work/travel buddy that lives in Warwick.

10-05-2016, 02:22 AM
Not sure about the 2 piece floor, thats just how the plans show it to be built. Would make a more comfortable ride if it were all one plane. You would get an additional 1-1/2" lower knees would be a little happier.

10-05-2016, 03:34 PM
I know that I adapted the front end to mine with very little issue so I don't see why it needs to be like that...we may never know!

Marlboro Man
10-05-2016, 09:40 PM
As far as the ride, yes some places to ride, mostly woods trails some dirt roads.

Ive got the Hobart Handler 140.

You are correct I started off with flux core, however I soon switched to gas. I found my welds were much better with less to grind off. I had to grind off the majority for the flux core welds and go back over the frame welds. My neighbor is a welder by trade, and after he saw me with the flux core, he helped me get the gas set up. I have him check my welds, as im a novice to welding.

As far as the lower floor question, im not sure why the plans set it up that way. I started off following the frame plans, but it looks like others have modified it.

10-06-2016, 02:06 AM
Sounds good.

What are your front arms off of?

They pretty long.

Marlboro Man
10-06-2016, 11:36 PM
2015 Yamaha YFZ 450 A arms

10-07-2016, 12:34 AM
Are you going to go with S10 axles?

Marlboro Man
10-07-2016, 01:30 AM
Yes, I wanted to use the S10 CV axles and the hubs.

10-07-2016, 05:17 PM

10-08-2016, 12:02 AM
Looks good, you have a great start. Can't wait to see how things progress.

Marlboro Man
10-09-2016, 10:53 PM
Able to do some work on the buggy in the garage today. Added some bracing to the frame. Started work on the rear trailing arms and the brackets.



Marlboro Man
10-19-2016, 01:08 AM
Spent some time working on the rear of the buggy over the weekend. Extended the rear about 20 inches to better accommodate the rear sprocket, CV axles and engine. As far as the rear set up, I'm going with the CV axles, same as Lug-Nuts and Wschilawski and some of the others. (Wanted to give credit to where it was due)Been looking on Ebay for some front and rear shocks as well. Still looking for a good set for a decent price. Rebuilt the front end a arm mounts as well. Had to spend an hour or so rebuilding the mounts as my tires were rubbing into the front corner of the buggy.

10-28-2016, 03:29 PM
Just started reading your build thread. I'm glad to see that there's still some action on the Shredder II front. It's a shame that they went away, especially without any warning, but it will be fun to watch your progress.

Marlboro Man
10-30-2016, 08:05 PM
Did some work on the front end over the weekend. Picked up some 18 inch snowmobile shocks. Tacked up the front shock mounts and put some tires on for clearance purposes. (I know the front tires are mounted in the wrong direction, just threw them on for mock up purposes). I'll try to get working on the back end over the next few days.


Marlboro Man
12-18-2016, 08:51 PM
Haven't been able to work on the Buggy for the last 4 weeks or so. Finally able to get back to working on this. Picked these up for the rear shocks the other day. Came off a can-am renegade. Started work on the brackets to mount the S10 Hubs.


Marlboro Man
03-03-2017, 12:18 AM
Worked on the buggy over the last few weeks. Got the trailing arms on, bearing carriers on. Working on hubs to attach s10 axles to 1-inch shaft. Keyway is taking some time to get finished. Need to modify the headers and work on the rear shock mounts. Able to get the engine mounted. Steering wheel and rack and pinion along with tie rod ends are coming in soon. Trying to figure out the electrical mess. Trying to figure out what parts I can take out from the wiring diagrams. If anyone has any input, feel free to add. Some forums say resistors need to be wired into some models, mostly the newer models, others say they did without. As I said, if anyone has ideas, feel free to share.




03-03-2017, 01:00 AM
You've made some nice progress. Keep at it!!

03-03-2017, 05:09 PM
I'd get the engine running with the complete harness and then remove the unwanted wires one by one, checking that it fires up after each wire removed.

Marlboro Man
03-03-2017, 11:35 PM
Ill take your advice and check the engine that way and remove wiring as needed. Ill need to figure out a gas tank before I get going.

Marlboro Man
03-20-2017, 11:50 PM
Got some work in over the last few weeks. Able to get the hubs made up for the brake, sprocket and CV axles.


03-21-2017, 11:04 AM
What your plan on keeping all tight on the keyway stock?

Marlboro Man
03-21-2017, 09:16 PM
Im going to lock them in 2 ways. Im planning on notching out the 1 inch shaft with 1/8 notch, then add 1/4 key stock for the keyed shaft, as the hubs all are cut to accept the key stock. Pictures dont show, but each hub has 2, 3/8 holes tapped for bolts. I prefer the bolts over the small allen screws.

03-21-2017, 09:30 PM
What size is that shaft? I went with 1.25...I will only be running 50hp though.

Marlboro Man
03-21-2017, 10:08 PM
Ill throw this out her as most of you have much more experience with these builds. I used LUG NUTS idea for a gas tank, by using the Harbor Freight air tank and welded a fuel filler neck in. Im wondering how to set up a valve or delivery system to get the fuel into the carburetor. The petcock that came with the donor motorcycle was all corroded and the on off switch doesnt turn. This had 2 outlets for the carburetors and one for the vacuum. See pic below.


Ill ask this and see if anyone can assist as I'm wondering if i just drill a hole in the tank, weld a nut with threads and put a valve in with a Y for the carburetor feeds or do i need to find a petcock that has the 2 outlets and vacuum outlet. I suppose I could have used the hole that was there for the pressure gauge, but my original plan was to cut a hole in the bottom for gravity feed of the fuel with the petcock set up. I found out that after i set up the tank, the petcock was in much worse condition than it was. Maybe someone has some ideas to help me, feel free to suggest or give your two cents.

Marlboro Man
03-21-2017, 10:10 PM
My rear drive shaft diameter is 1.25

03-21-2017, 11:00 PM
Wonder if you could use a pulsed fuel pump like from a snowmobile?

03-24-2017, 02:34 PM
You could get a tee for fuel line, and go with a single outlet petcock. If the motorcycle didnt have a electric fuel pump, then it was gravity fed.If you dont think that will work, then you can add low pressure 12v pump inline or in tank. I would put a fuel pump on there just so theres no worry when going up or down a steep hill.

03-31-2017, 12:19 PM
I recently converted a tank with a bad petcock to gravity simply by getting a 90-deg. elbow, brass barbed nipple and inline petcock. You could drill out and weld on an appropriate nut or pipe nipple, add the barbed with an elbow if need be, then "T" off after the petcock and inline filter. Whether or not you'll need a pulse or electrice pump is dictated by the carburetor type and float needle rate more than anything else.

03-31-2017, 02:25 PM

Marlboro Man
05-17-2017, 02:12 AM
Able to get some work done over the last few weeks. Had to abandon the gas tank for awhile as I had to get this thing off the lift in the garage. It was time to get it on 4 wheels. Now I can push it out of the Garage. I found some Polaris sportsman rims and tires off Craigslist pretty cheap. They had the 14 inch rims I was looking for with the 4 x 156 bolt pattern. Still need to play with the rear shock mounts, but it's on 4 wheels now. Created a chain tensoner, I used a spare sprocket, 3/4 shaft and 2 pillow block bearings. Not the best picture of it but it does the job.

Able to make the front steering set up. I had to make tie rods with misalignment spacers and heim joints. Used some 5/8 rod and 5/8 nuts and threaded the rods with a coupler for the heim jts so its adjustable if need be. My next project is the exhaust. Having a hard time finding weldable steel exhaust in 1 1/2 OD to match the tubing. Looking into some exhaust tubing benders to begin that process. I need to revisit the gas tank and the fuel lines and the electrical systems as well. I started trying to figure out what wires go where and labeling them so it will be easier when I try to fire the engine. http://i1243.photobucket.com/albums/gg554/marlboroman2016/20170516_212423%201_zpsojfdovtu.jpg



05-18-2017, 03:57 PM
Nice progress