GS1000G mods- big bore and fuel injection

[GS1000G Shopper]

More research today, which was spent primarily removing the front wheel & forks so I could replace the springs and seals.

The GSXR fuel rail has a 5/16 "quick disconnect" (QD) fitting on it. One of the project cars in my shop is a Dodge Daytona with the 2.5L engine. I had the fuel rail and hose off it and noticed the fitting looked similar to the GSXR part. I plugged it in, and it clicked into place.

I've found a number of Chrysler fuel filters with this type of fitting, but the thing is with Wix you have to look at them one at a time, and all of the specs are not there for each one. I'm looking for a small filter, and have seen a couple that may work- the fittings are both on the same side, one barb and one QD. Some versions come with a hose. The specs I've seen fro most Wix filters are in the 10-15 micron range, which should work well post-pump, pre-injector.

I'll update once I find something that works and is affordable.

[GS1000G Shopper]

My fuel pump testing rig paid off. The small pump draws about 2 amps free flow using water, but under pressure it spiked to 10.5 amps! It also leaked on the inlet side around the metal seam, so it was not usable- I'm sure this was due to plugging the ports. Plan B is the Bosch external version I had listed here earlier. I suspect it will draw less than this one based on the overall rating. Plan C wil be to use an early Hayabusa pump that has a built-in regulator. My only concern is the size.

The replacement fender is painted, the forks are resealed, the rear tire has been swapped and new bearings installed.

I also made a couple of oversize battery cables to replace the old thinner ones. I used some 6 gauge cable from McMaster, 8 gauge would have worked, but the 6 gauge was the smallest size with a high-temp covering.

I have a set of used throttle cables from a GSX1100G. It looks like they may be barely long enough, but it will be tight. I had to re-drill the plate on the switch housing so it lined up with the hole for the screw. The choke cable won't work since it can't be adjusted- usually these cables have two nuts and an adjuster sleeve. The GS cable only has one nut and it's actually too long for the application. I think a universal cable may work, or in the worst case I can use a GSX left control that has a choke control on it.

[Mekanix]

Why not an in-tank pump ? Seems to be lots available cheap.

that would require cutting into the tank and making a plate to mount the pump and seal the hole but you could get a whole unit with the plate built on.

Seems like an easier way to go price wise.

[GS1000G Shopper]

The layout of the GS tank is somewhat different than the later GSX ones. With the narrow sides, it may be a tight fit to get an entire assembly in there- I have not measured a GSX in-tank assembly, but from looking at them it appears it would be very tight, and could not mount in the rear. While it may mount towards the front, then you have to worry about clearance for the parts that hang down.

I had considered adapting a later model tank to the bike, but that would change the appearance in a way I would not like. My goal is to retain the stock appearance if possible, another reason for keeping the petcock.

Additionally, that is a lot more work than I care to do- and takes this from a mostly DIY level (excluding regular machine shop work) to one requiring costly third-party work.

[Steve]

Using these numbers with the 73mm pistons & large head gasket, I get 9.76:1 with the GS1000 head, and 10.7:1 with the GS1100 head.

I'll likely need to run a better grade of fuel if this is the case.

As you noted in a later post, compression ratio is not the only determining factor for octane requirement.

If your have a well-designed combustion chamber that is relatively small-diameter so the flame front travels quickly, you can do very nicely with lower octane. When you have larger-diamter chambers that might not have proper turbulence to propogate the flame front, things start going wacky, and the quickest "fix" is higher octane.

As evidenced by the picture on page 12 (copied below), my digital caliper had them at 72.88 mm. ...

What do you mean "on page 12"? This is only part-way down on page FOUR.

If you don't agree with me, you don't have your "view" setting set to a much more convenient setting. Very easy to change.

.

[GS1000G Shopper]

Thanks for the combustion chamber info. As for the picture/page/post, why bring up an issue that has been resolved? I'm going to houseclean this whole thread once the project is complete and use the first post as a table of contents so members do not need to wade through irrelevant research material.

[GS1000G Shopper]

The GSX-G throttle cables are too short by a couple of inches. I've been trying to find lengths for other models, but this is apparently classified information. Most places list the length as "standard". The GSX-G housing is 42", and I estimate another 2~3" would do.

I see Motion-Pro makes (or perhaps made) an extended length (+5") push/pull cable set for sport bikes, and the base number (021-281) fit an older GSXR1100. The only place I see that lists this is Sudco.com. The extended sets are $63, and I have no idea if they are long enough.

One other possibility is a set from the VL800 wannabe Harley model (I was surprised I didn't see one in their new ad but then again they all look alike to me ). I found M-P makes extended cables for these in +6 and +7 lengths. Apparently, the HD madness hits these owners as well, as one thread showed how to put 14" Ape Hangers on one. I'll not link it out of consideration for those with queasy stomachs. That particular project used a universal cable from England. The used VL800 cables I've seen on eBay look like they have the same ends, so if the length is right, these should work.

Solution: eBay seller ID steelescycle made a set for me for $25/cable. I ended up only using one. You need to have about 4.5" sticking out to hook up to the throttle bodies. The housing length I got was 47.5" + 4.25" for cable (51.75" overall), and the housings were too long (too long is workable, too short is not). A 44~45" housing (48.5~49.5" overall) would work fine. The housings must have 90 degree fittings at each end. I used a set from a 1992 GSX1100G as a template, they are almost long enough.

The GS1000G stem mounted choke cable will barely fit onto the fast idle cam on the GSXR throttle bodies.

UPDATE
I've decided to use the center linkage solution that is linked in the table of contents post. I was able to re-use the longer cable OK, so the shorter one would likely work but was not tested.

[salty_monk]

You can get custom cables made up at somewhere like Speedy cables.... There was someone who linked a company they used on here. Can't find the info offhand but a search might bring it up.

[first timer]

Try a local chopper or old time bike shop in your area, those are the places by me that do custom cables.

[Mekanix]

Airport! find a shop that does small aircraft. They use lots of cables and could make one what ever length and fittings you want.

[salty_monk]

http://www.motionpro.com/motorcycle/custom/

Doesn't seem much worse in price than a normal set & MP is a decent company... Pretty much the first hit on Google.

[1948man]

http://www.goldwingcycleparts.com/ecom/category/529/11/

Someone speculated these folks might do custom lengths.

[GS1000G Shopper]

http://www.motionpro.com/motorcycle/custom/

Doesn't seem much worse in price than a normal set & MP is a decent company... Pretty much the first hit on Google.

Looks like that will be the best idea to date. I can send in the GSX-G cables.

Heard back from an eBay seller as to the VL800 cables:
from tip to tip they are 42 1/4" and 42 5/8"

This is the same length as the GSX-G cables, but the +6" ones for the VL800 would work.

[GS1000G Shopper]

Photo updates-
Front fender repainting. Not a perfect match by any stretch, but not bad for about $10 of paint. The color is Krylon Burgundy. It was sprayed, allowed to dry, polished, then sanded with 1200 grit. After 4 coats, it was top coated with some polyurethane.




New battery cable, 6 gauge from McMaster.com:


More pics to follow in the next post.

[GS1000G Shopper]

Throttle bodies in place, they were a tight fit and I ended up using a nylon strap to install them (a trick learned from fighting V65 Sabre carbs). Some pics show the setup with the stock airbox, and others with pods. I think there will be room to mount the electric fuel pump in front of the stock airbox.


This pic shows the 45mm hose that goes into the stock airbox:


Pods: