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Ghost's 2003 Suzuki VL800 rebuild/custom bike build

9.8K views 16 replies 7 participants last post by  XJMatt  
#1 · (Edited)
Okay so after the new year started with me soon entering college I was at the point where I gave up on my VL800, went down to Harley and tried getting a new bike that didn't have so many issues after being refused due to me being young with horrid credit history by 14 different financing outlets I tried the only bike shop I trusted in town.....and they tried to screw me so hard I that day vowed to never let them touch my bike again and have been learning/repairing my own bike since, a week after school began I looked my bike up and down....for three hours just literally sat outside until sunset staring at my bike and decided since it has kept me safe and rubber side down in the 2 plus years I've been riding it through all the issues thick and thin I owed it to take a lot better care of it and build the bike I sought to buy instead. Chose working on the bike I fully own being its my only vehicle and I've yet to learn how to drive a car this will be quite a lengthy process and while its little progress here and there I'm making headway among the cries from friends and coworkers who ask why I simply don't just buy a new bike I'm going to list my plans here and keep updated with pictures since this forum is where I got most advice and ideas from (thanks guys!) and on January 29th I said screw the haters and began my tasks for the project

The list of things I seek to Do
(any advice is extremely welcome)
  • Front end bearing upgrades and fork seal replacements
  • Smaller LED black turn signals mounted in different locations
  • Removal of fork covers upper and lower
  • Forwards controls and new pegs in black
  • New headlight (LED upgrade if possible)
  • New seat
  • All chrome painted in a Flat black
  • All other parts painted in a satin black
  • Blue collar bobbers side covers to replace OEM covers
  • Replacement of all hoses and possible upgrade
  • Control boxes painted and switches replaced to new non faded ones
  • Stash tube installed to hold registration and title
  • Have been considering the DJ mod I've seen here
  • Coolant flushed and replaced
  • License plate mounted on the side

List Of Finished Projects
  • 2" rear drop (DONE)
  • 12 inch black apes(10 inch Mini Apes DONE)
  • removal of pair valve (DONE)
  • kuryakyn metric grips (DONE with cheaper, nicer eBay knockoff)
  • removal of rear seat, sissy bar, and backrest (DONE!)
  • exhaust either ceramic coated in black or painted by myself[/strike] (DONE)
  • might do a exhaust wrap for pure cosmetics (Did do an Exhaust Wrap)
  • new spark plugs (DONE!)
  • Clutch upgrade (DONE!)
  • After-Market Air Intake (DONE!)
  • New battery (Old Battery finally crapped out, gold standard Autozone Battery) (DONE!)
  • Carburetor rebuild and deep cleaning (DONE, partially!)
  • Carb Rejetted with Dyno Kit (DONE!)



basically going for the blacked out low-rider look

looking to make the bike mine and want that sense of achievement

first Pic is the bike in 2013 almost right after I bought it from roommate

next pic is bike today after some work already done (not no it has not taken me two+ years to do all this actually was was recent I took all the back seats off

will keep updated and pictures will come too
 

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Discussion starter · #4 ·
Been looking at the m50 fender, not sure if I want that or do I want something to hug the wheel more was thinking on getting a taildragger rear fender and cutting it straight across to my desired length

As for the rims, idk might just try to find custom being my vl800 has extreme sentimental value to me, some more to add to the list when I get home from school being I forgot some lol but the entire project is coined as

Project Thunderhorse, and yes that will be replacing the volusia on the tank one day
 
Discussion starter · #6 ·
I meant replacing the bearings as in going from free ball to a new type of bearing will link here but both a front wheel and swingarm kit exists

Also, when I mean sentimental Value I mean the bike will never be sold, Im more than capable of spending a couple grand on a bike I never plan to sell, and 2500$ value!?!?! Everyone down here wouldnt even touch 800$ on a trade in value for my bike where do you live ill go there and sell it lol

Its a project, something to keep me busy like building up an old hotrod or non special car....not to sell, just to see it in great condition and admire the fact that you didnt let the factory decide what bike you want

But thanks for the input about the rear tire, sucks but meh
 
Discussion starter · #7 ·

that is the swing-arm factory restore kit, know it says 05-13 suzuki but it also pops a message since my bike is saved in Amazon that it will fit my 2003 vl800


that is the steering head bearing upgrade kit replaces the traditional loose ball design


front wheel bearing kit, scroll down and read the list...it supports an '03 volusia

also yes I'm aware of the price tag, parts list on Amazon alone is 1,900$, but being I paid 1,500$ for the bike (over the course of a year mind you) and I currently have a high paying job as a butcher and am in college to enter the electronics field I have the extra funds needed to do something radical like this just for the heck of it

I do plan to buy a street bob down the line and trick that one out too but that is far off as I'm paying my monthly bills down to having almost 70% of my income free for goodies don't want a bike payment ATM and would rather hold off on paying for bike insurance as well gotta love Florida one of the last 2 states that don't require insurance if you completely own the bike, I pay 32$ a month for my bike and that is it lol
 
Discussion starter · #8 ·
Okay so, 3/25/16 update

New 10" mini apes, new grips, dropped the rear one inch, and removed the pair valve

Working with that rear tee for suspension waa brutal I was about to shoot the thing, and the pair valve .......they say do all the crap to reach the front tube but it didnt help lol so my sausage fingers inside a 2 inch wide area doing quarter turns on a wrench, took me over an hour to remove the front air tube

But it start, rides nice, and looks nice, will eventially replace the mirrors, been too pissed about the bike almost immediately falling over 2 years ago and snapping a brand new mirror off
 

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Discussion starter · #9 ·
Okay small update today, tried my hand at painting for the first time, went pretty well coated and primed twice after sanding everything for 2 hours, seafoamed my fuel system and saved some for the next oil change, decided to add a personal touch to the air intake cover, needs some touching up but thatll come my next day off work but first pic is before rest is after going good, slow but good
 

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Discussion starter · #12 ·
Progress happened today, finishing up my exhaust here soon, choke cable finally installed after 2 years without one, kickstand springs replaced, upper exhaust wrapped mufflers drying as I type then on the bike to be cured, long productive day, group of guys who all ride together down my street stopped by when im guessing one of em spotted my bike in pieces again lol gawked and questioned for a bit and they rode on, monday ill be doing the fake engine chrome pieces ran out of time today
 

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Discussion starter · #13 ·
Nice job looks great


what did you do to the chrome parts before you painted them ?

I was actually stupid with what I did, didnt think to strip the old paint to make the plastic parts easy and I sat out here numbing my hands with an electric sander for an hour each time then thrice coated self etching primer sealer (which was a light black) and sprayed two coats of the paint
 
Discussion starter · #15 ·
Okay so loads of work happened being im on vacation

Got alot of engine problems taken care of Thunderhorse is all but a valve adjustment and a coolant flush away from being mechanically upgraded

Things that happened this week

New Clutch
All Barnet all brand new ...hell even ordered fresh washers for the basket, Friction plates (soaked for over 48 hours in fresh oil), pressure plates, springs, new bolts, gasket acetoned the clutch cover inside to remove any gunk

Seafoamed the Crank case, now I put about a 5th of the bottle in the oil, idled for 10 minutes, let cool drained old oil....and sludge, let air dry in the heat, flushed twice more with new oil strained every time until nothing came out, a noticeable smoother idle.

Dynojet stage one installed, carb gaskets replaced, carb re floated with seafoam and gas tank took the rest of the can, stalled alot at first died maybe three times ....now runs smooth test ride after new K&N filter installed with cleaned air box and hose to carb bike breathed for the first time in a while ...filled up and hummed all the way home

Differential oil change with drive shaft molly pasted along with lube on the axle side of differential, this along with new clutch, liquid smooth shifting.

Had its fair share of ups and down, after rejet and air it developed a habit of throwing itself out of 4th randomly, got to a point I was punting the shifter. Loads of corrosion on bottom bolts for clutch cover, all soaked in PB blaster and then cleaned, ordered all new ones.

Special thanks to Youtubers Maraggie, TwoWheelobsession, and dawino6260 for their videos on how to do most of the stuff here

Bike shifts like new, brand new clutch fully adjusted and took for a decent ride ...liquid smooth instant response ........a dream
 

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