Naked TL1000S long term tinkering build...

Discussion in 'Some Assembly Required' started by Wheedle, Jun 14, 2018.

  1. Wheedle

    Wheedle I love inflatable fun!

    Joined:
    Apr 11, 2004
    Oddometer:
    3,891
    Location:
    Newnan GA
    First, the background-
    I've known his bike for at least 12 years and the previous two owners ( one guy owned it twice ) and had been offered the bike twice when I couldn't make the finances work. I'd rudden it many times, even did a trackday on it. I've always loved liter twins, and to get my hands on a 97TLS was always on the list. Finally, the last owner called me up and made me an offer I couldn't refuse. It had been dropped by an earlier owner, I'm sure, thus the beginnings of the naked conversion. Some of the work was a bit janky, but the basics are solid. 97 TLS with 25k, PC3USB, TLR clutch ( 6 springs and bigger) , TLR rear wheel ( 190 tire instead of a 180, turns just as well with the newer 190/55 profiles) , a nice Pro-taper bar, and a raucous set of Two Brothers exhaust, a Vapor gauge and a pile of spares thrown in. The mapping was all over the place, the clutch cover leaked, and the clutch switch had been jumpered ( part of the mapping problem). But it was just a beast when it was running right.

    This build ( rebuild? ) will probably take quite a while... we just bought a new home, have our old home to get on the market, and I also have an Audi B5 S4 to tinker with, and a 6 year old son. So, bear with me. I picked it up last spring, so I will catch it up in his first post.

    I picked the poor neglected thing up in the rain. It hadn't run in a while, leaked from the clutch cover, needed a new rear tire, and fairly well refused to run under 3k. I also re-discovered that the gauges were either bad or had been monkeyed with. The speedo reads about 15mph high , and the tach wont read under 3.5 when the engine is running. The tach also seems to read about 1-1.5 low. I'll eventually wire up the Vapor which should cure both those ails, and clean up the dash a lot.


    [​IMG]

    My son picked out a strangely suitable keychain for it.

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    #1
  2. Wheedle

    Wheedle I love inflatable fun!

    Joined:
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    So, for a few weeks, I fought with the factory clutch cover and it's horrible leaks. I tried the old standard fixes of shortened, then flanged, bushings, gasket sealer, and different o-rings before giving in and making a new cover.

    [​IMG]

    Oil leak fixed, it was time for some riding and tinkering with the mapping. After some research, I discovered that jumpering the clutch switch would cause it to stay in an ultra rich map state, so that got replaced. Then I made a transistor TRE. These two helped a lot, but the mapping was still off. So, I've been tinkering with that along the way. I have something workable, that has really cleaned up the low-end part-throttle response, but i need to take some fuel out up top I think. Regardless, the thing is a bit of a beast. If you've never ridden the un-neutered 97 TLS, it's a different animal han he later bikes for sure. I also spooned on a new Pirelli Diablo on the rear. The next set of tires ( which will likely be soon, this thing eats rears) will be a more current offering.

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    As she sits right now the short list is -
    Continue playing with the mapping
    Machine up a much nicer headlight mount
    Wire up the Vapor
    Install a larger bore radial m/c
    Machine a quieter set of inserts for the exhaust, it sounds great, but it's a bit on the loud side.
    Sort the forks a bit, stiffer springs and fresh oil.
    #2
    MATTY, shinyribs, larryboy and 5 others like this.
  3. Wheedle

    Wheedle I love inflatable fun!

    Joined:
    Apr 11, 2004
    Oddometer:
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    Location:
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    It's always kind of funny how many people think it's a first gen SV650.
    #3
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  4. Egoland

    Egoland Adventurer

    Joined:
    Jan 13, 2010
    Oddometer:
    65
    Location:
    Denmark, Scandinavia
    Got a '97 TLS. Got the same clutch cover problem. I countersunk the the boltholes in the block to make it thight, and it worked for me. Also got a wide bar on mine, and the sixpot caliper. A good mod is converting to a standard piston shock in the rear. Mine is a Hagon, and it works a treat!
    #4
  5. MATTY

    MATTY BORDER RAIDER

    Joined:
    Jun 23, 2014
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    Looks to be a interesting build project, i look forward to seeing this evolve i am fond of the TL1000s never owned one but rode on a couple of times i liked the grin factor.
    #5
  6. yeroc40

    yeroc40 Long timer

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    Oct 11, 2006
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    Neenah, WI
    I miss my TL badly.

    Probably totally irrelevant with the PC3 but, do you know if the ECU is original 97 or the recall replacement? Mine had the original for a while and the low speed on/off throttle was miserable. Word was it made more top end, but was not fun to ride in the real world. I ended up trading it off for a later ECU that helped a ton and honestly, it still had more stomp that I knew what to do with.
    #6
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  7. Fubars

    Fubars What would Scoobydo?

    Joined:
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    Oddometer:
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    Ventuna, California
    I picked up a dead '97S last November---for $100 cash. Got it running after new fuel pump and injector cleaning. Now I'm fitting a Fox shock from an R6 and then I'll strip it to the frame to fix the cracks up near the radiator mounts. How's your frame holding up?

    Is that a Speigler bar kit? I want to get one for my bike.

    Nice job on the clutch cover. I lucked out with mine. Filed down the dowels, black RTV and it's been dry the past few months.
    #7
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  8. Roadracer_Al

    Roadracer_Al louder, louder, louder!

    Joined:
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    2,193
    Location:
    Oakland, CA
    I'm in because I received 1.5 TL-R motors in a box from a friend. I have plans, and I need to get to know people who know things about TLs.
    #8
  9. Fubars

    Fubars What would Scoobydo?

    Joined:
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    I've been lurking on TLPlanet and TLzone since I've had mine. Plenty of info there, but PhotoSucket has killed a lot of good threads on those forums. Get a factory manual. You'll need it.

    Day of purchase

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    Done so far

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    #9
  10. Skellington

    Skellington Pro Coffee Drinker

    Joined:
    Jun 28, 2014
    Oddometer:
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    Location:
    San Francisco Bay Area
    Nice looking TL - I had a 97 TLS and for sure that is a fun engine in those bikes with all that torque. Suzuki really made a statement when this bike came out .
    Have fun with the build !
    #10
  11. Wheedle

    Wheedle I love inflatable fun!

    Joined:
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    Oddometer:
    3,891
    Location:
    Newnan GA
    A rear shock conversion is farther down the list. I think I know where I can get my hands on a LE linkage for a shortened Penske to copy. I'm a fan of Penkse shocks, both the Strom and the HawkGT have them. I am a machinist, so most bits will be one-off. The bar conversion was originally just a drilled top triple with rubber bushings, but I reworked it with more strength in mind while my old roommate had it. IIRC it has the original ECU. The PS3 changes fuel, but the ECU's had different timing curves, different switchover points for cold map, and a couple other things. I know one thing, she is a cold natured beasty... won't run off fast idle below 100, and really doesnt run right until 180 or so. It has the engine temp sensor relocated to the housing in the V, the original was in the rad, which apparently caused some of the mapping issues with the early bikes. I've gone over the frame several times over the years, and there is no apparent cracking. It only has about 27k on it right now. I'm torn on the 6pot calipers. My old track GSXR750 had them, and I loved the power, but I can't quite get the same feel out of these. If the new M/C I have sitting and fresh pads don't fix it, I'll be looking for some 4-pots
    #11
  12. Fubars

    Fubars What would Scoobydo?

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    Have you thought about upgrading the master cylinder? The R1's have Brembos. I might get one on eBay later after most of my other mods are done.
    #12
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  13. ADV8

    ADV8 Long timer

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    North of Sydney.
    The TL1000S is a good bike, I have a couple.

    There are plenty of mods you can consider to improve a few things.

    [​IMG]
    #13
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  14. Wildebeest90210

    Wildebeest90210 Long timer

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    I got a Aprillia Brembo radial m/c from a mille, on fleabay. The seller hadn't put Brembo in the description making it a third cheaper than similar models.
    #14
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  15. ADV8

    ADV8 Long timer

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    As far as the cooling on the 97's you might want to look at the thermostat type and rating also if not done already when updated to the 1998+ set up.
    Both of my 1998 S's have factory restrictors (6 mm ID iirc) on the cylinder head coolant fitting but can't remember if it was the front or rear cylinder. (it is only one fitting restricted)
    Any TLS (with the later cooling set up and ECU ) should fire up like clockwork, full fast idle lever from cold and the rpm should rise once it comes off the cold start map around 81 C.... then back the fast idle lever off for a smooth idle.
    #15
  16. Wheedle

    Wheedle I love inflatable fun!

    Joined:
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    When my old roommate had it, he updated all the cooling. I don't remember what all he did, but I do know the thermostat and housing was changed, and the ECU reads from the engine side of the T-stat. 81c is about 170f, so that sounds about right. I'll look into the restrictor, but I want to say he did that too. He was very particular.
    #16
  17. Wheedle

    Wheedle I love inflatable fun!

    Joined:
    Apr 11, 2004
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    Location:
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    I have a Nissin 19mm radial m/c sitting. I need to order the banjo bolt for it.
    #17
  18. Egoland

    Egoland Adventurer

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    Oddometer:
    65
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    Denmark, Scandinavia
    I know some have fitted a temperature sensor from the Suzuki Baleno diesel to make it run cooler. I fitted a simple switch on the sensor to switch the fan on, when it gets a bit hot.
    #18
  19. Wheedle

    Wheedle I love inflatable fun!

    Joined:
    Apr 11, 2004
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    Location:
    Newnan GA
    Yeah, after realizing the fans don't kick on until 220 or so, I've been contemplating either a manualmswitch or a temp sensor switched workaround.
    #19
  20. BLZ2DWL

    BLZ2DWL Roustabout

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    Reddish Knob? Quite a trek from Newnan, GA, isn't it?
    #20