Rebuild: Magic School Bus II: no squid left behind

[The Magic School Bus]

It's been awhile folks! After my catastrophic crash, 6 months in recovery, I'm physically ready to ride again. I'm planning on going back to Austin, TX from central FL (a trip I made in late September) to watch MotoGP at COTA.

After much consideration I've decided to rebuild my 05 for many reasons. It's a difficult job but I'm inclined to enjoy a challenge. The hardest part is going to be completing the job before I set out on April 6, about 3 weeks from now.

I'm posting this to ask questions about how to do rebuild safely and efficiently. Most of the bike is still in excellent condition. The frame is solid. Following is a list of parts that I need and if anyone has advice on how to fix them or replace and where to get the parts or tools other than the obvious Suzuki parts suppliers please share your knowledge here. Thank you.

Subframe
Upper cowling
Headlight
Turn signals (front)
Fender (front)
wheels (front & rear)
Fairings (left & right)
Rear frame cover
Muffler (right)
Passenger pegs (left & right)

Upper crankcase, case cover (left & right) (I found someone selling an 06 engine, so at this time I plan to do a swap which should be less time consuming anyways)
Forks & steering stem (pending purchase from 06)

 

[The Magic School Bus]

Questions re wheels: are gen2 and gen1 wheels interchangeable? can these wheels be fixed, how much might it cost, what kind of shop may do this?

 

[sixpack577]

Gen1 and Gen2 wheels are not a direct swap.
I would scrap those damaged wheels.
The R1 wheel swap is also an option, less weight for around the same cost, but you'de have to search for the details, as I don't remember them.

 

[The Magic School Bus]

Gen1 and Gen2 wheels are not a direct swap.
I would scrap those damaged wheels.
The R1 wheel swap is also an option, less weight for around the same cost, but you'de have to search for the details, as I don't remember them.

Thank you! Are you saying the R1 wheels are not a direct swap either?

 

[sixpack577]

Thank you! Are you saying the R1 wheels are not a direct swap either?

No, they are not.

 

[The Magic School Bus]

Question re: exhaust. Are the gen1 & gen2 mufflers interchangeable? (not the headers)

 

[sixpack577]

Question re: exhaust. Are the gen1 & gen2 mufflers interchangeable? (not the headers)

If I remember correctly, gen2 mufflers will bolt to a gen1 header on a gen1 bike.
But that you'll need to fab a short bracket for each side(with a bolt hole in each end) because the passenger peg muffler mount points on the gen 1 and 2 are not in the exact same location.
I think it was @Dehning that had that set up yeats ago