Fazz711

Helicoils are fine if done right. I would use them. Timesert are bit more suited to the application but as said expensive for a one off.

As long as it is put together properly should be no problems. It will be under more stress but the engine is a very strong unit to start with.

Yes at 89 could be a import that got wrong year reg. Have heard of that before.

Not sure on 750 as I think all two valve 750s were kick start

Blueing is from the heat treatment to harden the teeth.

#wraith has done LED conversions

It would be easier to swap engine than swap Suzuki shaft to chain. Something like bandit or power screen motor.

Lush

Agree with others the AC seems low. If you have a good battery charger and you are fully charging the battery it should run ok for a while. Worth trying to check if you have something draining the battery. Run an clip on amp meter if you can on try running multimeter in line set on amps I also suspect you have now got a duff battery.

Welcome to OSS. Nice project. We need lots of pics

Anything 5/8 or 16mm will do.

I think the GS1100 will be the four valve motor as in USA that was their designation not GSX as the UK four valve was. Nearest equivalent to two valve GS1100g would be two valve GS1000. Some of the four Valve are twin shock some are mono. A pair of shocks for GSX et would probably not be far off

Dose the sun frame have extra braces? Most race bike don't use them if they are fitted as it is extra weight they can do without. Also a lot of the electrics are trimmed back to bare minimum.

Oh do jealous I love astalites

530 are now much better chains. No brainer really

Great reading.

Another vote for Philpots Had quite a few done over the years and all been very good.

Normal bulb or LED?

Bit of stainless steel rod of the right diameter and length will do the job

I don't think so but others will confirm

Have you checked the routing. Had it in the past and it made big difference

Have a look on some of the 3D printer sites. I am sure I saw some a while back. You may be able to download the file and get the dimensions of it.

May be Davida Think they did a steel one that looks very similar

Rasska are nice but the last set I bought the quality was a bit iffy.

Glad she is getting better. Hope for full recovery.