Joe G's 1100 project

[Joe Garfield]

I thought I would start a thread dedicated to my bike, a 1982 GS1100g. It is a little more of a project than I realized so this will help keep me organized and serve as a reference for related issues. Let me first say that I am looking forward to the project, am excited to learn, and I got the bike I want.

Background:
The bike has 38,000 miles and an 'odometer discrepancy' so I can't really comment on the miles. It clearly needs all engine gaskets and most seals replaced. It does not start easy, and when it runs the exhaust pops and the engine runs hot. The whole bike smokes a bit - the exhaust smokes after sitting awhile, and the engine smokes under the tank due to the oil leaks and heat (presumably from the tacho seal but not 100% certain). The charging system was pretty weak and the battery died after a hard start attempt. I have since re-routed the generator directly to the R/R and the charging system is at the minimum acceptable level. Both stator and R/R are aftermarket, installed by the Previous Hack. I will post numbers below. Not sure what I'm forgetting... well except the leaking gas tank seals/petcock

Status:
I got some good advice to check the charging system before digging into the engine gaskets. Before attempting that I swapped the exhaust for a set from a 1000L so my neighbors wouldn't go nuts. I also installed a new tacho seal and gasket. I ran the tests as outlined in the Stator papers, and my plan is to check the stator output one more time before I begin the tear down (to avoid opening the generator cover gasket more than once). I will order all new engine gaskets and seals and a new OEM petcock. Carb will be cleaned with a local member, and valves adjusted after reassembly. At this point I'm leaning toward a new stator and maybe a new R/R but will decide after posting the data.

 

[Rob S.]

Not sure what I'm forgetting...

Year and model?

 

[trevor]

Year and model?

It's in the first line. Lol

 

[Joe Garfield]

Charging System

Charging System

Some good news today - I re-routed the 3 stator wires directly to the R/R and put a new connector on the R/R positive to wiring harness. Also I cleaned off the wire contacts at the battery terminals. I got between 13.6V and 13.9V across the terminals for idle, 2000 rpm, and 5000 rpm. I also double-checked the stator output voltage as it was earlier and the bike was running better, and I had a better connection than the other day. The charging system test went as follows:

1) Battery potential @ 5000 rpm: 13.8V
2) RR+ to Bat+ @ Idle: .033V
3) RR- to Bat- @ Idle: .208V
4) Stator Lead Resistance: 0.4, 0.5, 0.6 Ohms
5) Stator to Eng Case Resistance: 0L, 0L, 0L.
6) Stator Potential @ 5000 rpm: 70V A/C
7) RR+(red) to Stator Lead (blk): 0L, 0L, 0L
8) RR+ (blk) to Stator Lead (red): .448V, .449V, .419V
9) RR- (blk) to Stator Lead (blk): 0L, 0L, 0L
10) RR- (red) to Stator Lead (blk): .459V, .454V, .446V

I have something like a 0.2 Ohm resistance in the ground between the RR and the Bat, so I will chase and clean connections during tear down. I had 14.28 V between the RR+ and Bat- at 5000 rpm so I'm really happy with that. I also need a new battery - it's working for now but losing a little too much under load. I was about to get one but figured I should wait so I don't waste an off-season.

 

[Rob S.]

It's in the first line. Lol

Thanks to editing...:xsmilie_mrgreen:

Now the only thing you're forgetting is pictures! Show us what she looks like.

 

[Joe Garfield]

Yes, added the model/year to first post after Rob's reminder. I added a pic too. Here's one more - I need to get some better pics, and learn how to post more than one at a time.

 

[Steve]

I need to get some better pics, and learn how to post more than one at a time.

From "the library": Posting Pictures to GSR.

.

 

[Rob S.]

Now that's a good-looking bike. Nice siding and deck, too. :xsmilie_mrgreen:

 

[Joe Garfield]

Thanks! I will gladly accept compliments on the bike The pic is from the Craigslist ad. I think this bike is going to come out nice.

I just bought a bunch of small stuff from KYHNC.com, a Kawa/Suzi dealer in NC. I was randomly searching the web for a part that seemed to be out of stock (center tank pad) in a few places and came to their site. They have all the 'cheap' gaskets/screws for under $2.49 so I bought about $50 worth of small parts. Hopefully it is all legit. Tomorrow I will update my spreadsheet and start ordering the rest of the engine gaskets.

 

[Steve]

I was randomly searching the web for a part that seemed to be out of stock (center tank pad) in a few places and came to their site.

No need to do any "random searching", just go to Parts Outlaw. :-k
CUSHION, CENTER 44541-34500 $6.56

Just keep in mind that virtually none of the online vendors have all (or any) of these parts in stock, and will have to order them from the main warehouse(s).

.

 

[londonboards]

I've got a couple of these beasts myself and some time ago I put together a thread that contains all the best of this Forum for this bike in one post. Have a look here:

Ultimate Shaftie GS1100 Thread

It will give you lots of good advice.

Greetings

 

[Joe Garfield]

Interesting. My bike lists P/N 44541-49400 which is out of stock at many places, and cross-referencing at Alpha says that part is only on my generation G (82-83 G and GK). Maybe they used the leaf of a different rubber tree in the mold or something (joking). Considering it's likely all coming from Suzuki Japan, I don't know how it makes sense for one supplier to list it available and others to say its out of stock

Anyway I was happy to save a few bucks on quite a few "2.49" parts - even after shipping - so it should all work out. It looks like Monday might be the last day warm enough to ride for a while so I'm in no rush. With the charging system working, the tachometer seal no longer making a mess, and the starting troubles linked to a faulty fuel cock, I am feeling pretty good about things

 

[Joe Garfield]

I've got a couple of these beasts myself and some time ago I put together a thread that contains all the best of this Forum for this bike in one post. Have a look here:

Ultimate Shaftie GS1100 Thread

It will give you lots of good advice.

Greetings

Thank you, Sir!

 

[storm 64]

Yeah Mr.Garfield, I think your motorcycle will clean up real nice. It looks to be in about the same condition as my 82 850 when I got it. How is your exhaust system? Mine was okay i did remove it to clean and wire wheel and paint the pre-muffler. There are a few more things I have to do. Like you said we have all winter... I think you'll like your 1100G very much."Mr Garfield" inside joke from his other thread

 

[Charlie G]

Congratulations on a fine bike. I have an 82 and an 83. Just got the 83 running last August and have put close to 4500 miles on it since. Fantastic, comfortable ride, which is able to keep up with most others, assuming you have the skill and nerve. You sure live in the heartland of GS owners. Be sure to tap into their knowledge.

cg

 

[GSX1000E]

Although the GS1000G is arguably the best all-around shaft driven G model, the 1100G is the cream of the crop. :encouragement: (I have 3 if you count the GK)
The seat on the 1000 is a little better but the 1100 seat can be modified to be similar. The extra stroke of the 1100 engine adds enough torque to notice a difference.
Besides, the 1100G has nicer rims and fuel tank design.

 

[Joe Garfield]

Thank you! I am excited for this bike. My last bike was a 2001 Triumph Sprint, which was really top heavy and really long, and difficult for my to handle well. It had more than enough power at normal riding RPM but I was never able to find a smooth sweet spot for accelerating from a stop in city driving. The 1100g has both of those things.

I would like to see the difference in seats - the seat is one thing I have been wondering what to do with.

I had an '82 650GL, it was a great first bike. I thought I was going to get an L when I joined this site a few weeks ago. However, I got to see Steve's stable and compare, and was immediately hooked on the G. The 1000 or 1100 seemed like a no brainer since it's the same size as an 850 and technically a few lbs lighter. I find that it is very versatile in terms of riding position - you can load it up with baggage, windscreen, floor boards if you want.. or you can set it up for a more forward/aggressive position (which is my plan - slightly lower bars, possibly move the pegs slightly aft...). It has the power to do both well, and I was happy to learn it doesn't have the 'step function' power band of the 850 (just personal preference). It has great low end power for riding around town, plenty of top end power to cause trouble, and seems to be happy anywhere in between. Of course, when I get it all tuned up I might be in for a pleasant surprise

My exhaust looked OK- most of the surface rust was on the header pipes and the mufflers looked good. What I didn't realize was it had been drilled out and the baffles removed. It was a clean job and looked decent but too loud for suburbia and the bike is running too lean as it is. I bought a set of gently used L pipes off another member and they installed OK - not perfect but they don't look bad and they will certainly hold me over til the rest of the repairs are done. I have been thinking a little about a mod down the road but haven't put too much thought into it yet. I was happy to see the L pipes all hooked up and working.

 

[Joe Garfield]

Photo test: A few more pics from the craigslist ad. I don't know how old the pics are, the bike doesn't look that clean; there were a lot of oil leaks when I got it. My garage is not big and my trailer's blocking the door at the moment so I don't have room for fresh pics. That will change next week.







Also a couple of pics of an ignition coil. You can see how much of an oil mess is being made under the tank. And those coils sure look their age!

 

[londonboards]

Joe - I made the following mods to my 1100G for longer distance comfort: Long Distance GS1100G Mods and found the changed peg position to be the most helpful of all:

These were from Raask in Sweden. Expensive and not the best quality but they were made for the bike. You might find something locally that you could adapt. Putting your legs further back allows your legs to help support your body weight rather than the usual US sitting position (cruiser style) in which the whole body weight is supported only by your butt.

Greetings

 

[Joe Garfield]

Thanks Richard, I have been looking for pics of a similar bike with rearsets.

I need to start working on the engine gaskets and carbs. After getting the new muffler installed I ran the bike just enough to test the stators, and the new headers are already discolored. Maybe I will start taking things apart this weekend. It has been really busy at work, especially with 2 classes going on at the same time.

I did try a little polish on my mirror stem. I am amazed at how so much rust basically just wiped off. One of the stems is a little pitted still. I also was playing with the mirror angle and it started to come loose, so I figured now is a good time to learn what holds it all together. The internals look easy enough to repair or replace. I have one dent in the back of one mirror that I want to try to pop out first. I am bad with the 'before' pics, but I will try. Although I don't know what that's worth since apparently my photos are vanishing...

Does anyone have a good link for a homemade lift or stand that works well with the GS bikes? I am thinking I'd like to have the frame on a dolly but am open to suggestions. For a longer term project a traditional hydraulic lift doesn't seem to make a lot of sense.