DAZ

If it's a 2002 (mk2) you'll probably have to swap to mk1 inlets too as the later ones (bsr carbs) have a different spacing to earlier gsxr/mk1 bandits (bst carbs)

Just out of curiosity did you have a 750 head to compare to the 600? was it that the head of the b6 had a shallower combustion chamber than the 750 do you think kind of like the dot head vs 11/1200 head different chamber size ?

The 771 wiseco pistons that Clive has are still listed on us sites and wossner list similar for long stroke motors @£640/650 ish ...... Soon adds up to 11/1200 money

Well I think the easiest / most cost effective is long stroke 750 barrels and pistons but still got to factor in the seals and gaskets vs a known runner swap. I wonder if there are any differences in the 600/750 long stroke heads e.g. Valve and combustion chamber sizes that may add to the swap ?

There used to be a 884 conversion but if I remember it needed the cases boring to suit the big oversize liners ...... Set of slabby/long stroke 750 barrels pistons maybe ? More practically this

That is very similar to what was done on that xj650 ! Except he used one like this

No mine was a 1200 with twin k&N ovals and a st3 Dyno jet kit,never put it on a Dyno . I don't know why the 600s seem so sensitive to pods wether it is the smaller amount of airflow creates a weaker vacuum as it passes over the jets I'm not really sure tbh . On a different note a guy I knew years ago built a chop based on an xj650 single top tube dropped seat rail type frame and modified the air box so that he used the front section then fitted a plate over the hole where the rear section was removed and to that plate fitted old Brit bike style round air filter would something like that work on your build ?

Just remembered that early slabby 750s used 29mm flatslides ..... But probably rarer than unicorn poop

If you are serious about rs flatslides on a 600 bandit/gsxf, the 34mm is the smallest they do as far as I am aware, 2mm up on the stock size more than enough for any n/a 600. But unless you are competing in a capacity limited series you really would be better of with a bigger engine as a starting point... In my opinion for what that's worth .

Yeah my gs1000 had similar issues needed the basket re-riveting too ... Unfortunately I always seemed to want bigger,better,best when I was younger and was always swapping bikes when really I should have kept some of the better ones and had fewer changes ...

No it's a creative engineering solution ...... Ok yes it is a bodge but it sounds better

Also ask to see receipts for parts and work done , way back in the mists of time I bought a zed 1000 tuned up with similar mods to your Suzuki and it came with a stack of paperwork to prove it , went to see a gsx1100 that had claimed big bore Etc no paper trail and an owner who barely knew what it was, claimed the tickover was set high because of the race cams ...... no, when I turned it down the clutch basket was rattling like a bastard ....

I would have thought DW would be able to advise on jetting, he seems to have plenty dyno time ,but as @Gixer1460 the says ideal would be f.i. Possibly using 1250 bandit)/gsx throttle bodies, inlet rubbers and ecu, I think @imago is partway through this conversion on his 1100g but is about to move so it maybe on hold

As @Oilyspanner said hard to tell in a photo, a good feel especially over the 'nose' to make sure there is no pitting or ridges use your fingernail as well as your eyes, if it doesn't feel too worn or pitted then check that the lobes still have all the lift that it should with a vernier caliper . If they are worn then try somewhere like Kent cams who can regrind and harden your cams (suz7 is close to the std gsxr profile I believe) as any used ones are 30+ years old and just as likely to be worn .... Edit: the biggest cause of wear in my opinion (for what it's worth) is that they aren't used enough and the top end drys out so when it gets started after a month or more sometimes there's initially no oil on the cams ...

£5 deposit..... That's about a costabucks fancy coffee these days... Bah humbug grumpy old man face gif required

Not 100% on this but I seem to remember that some of the sv650 had preload adjusters so may fit your b6 forks .....

I believe the early gsxr 600 k and 1250 bandit have been used on oil cooled bikes not sure about air cooled

The mind boggles.....

I'd try the air box if dual pods won't work for you, might look more original/sleeper if that's your aim , I'm sure you could cut and shut it without too much hassle, either plastic weld it with a soldering iron or maybe some sort of glue.... Mek maybe as a few on here have used it to repair panel's though that was making some kind of filler iirc heck even pop rivets and silicone if it's out of sight, though that bike looks too nice for that kind of bodgery

Surely boost is only one part of the equation ? Maybe I am wrong (and if I am I welcome being corrected as it is the only way to learn ) but is boost not just a measurement of restrictions in the intake system ? E.g. If bigger throttle bodies or intake valves or porting allows more flow into the cylinder then the same amount of air would result in less boost pressure as measured in the plenum but the same cylinder pressure ? Is it cylinder pressure that causes the Detonation an collapse of the ring lands (diesel-ing?) So maybe altering the valve timing to reduce cylinder pressure at lower rpm ? Would 9.5:1 at 10psi but with better head flow be as powerful ? And still fit the formula ?

Looks very nice

I'll start by saying I have no knowledge of piston design but when I saw your idea to modify the crown of the pistons I immediately thought of diesel pistons I have seen that shape (ish) maybe this helps maybe not but it is an area to research as regard crown shape an squish perhaps.....

Then I think it is time to source a set of foot rests and fabricate some adapter plates to fit them

Regarding the footrest assy measure the mounting points and post up the distance between them , I know @fatblokeonbandit found out the rear sets off a wn model gsxr ( i think ) fits the bandit so maybe the 'Zuma is the same .... Presuming your knees are bendy enough for rear sets of course

You never fail to impress @clivegto with your can-do get to it attitude to making stuff fit