80 gs1100e teardown/rebuild

[loud et]

noooooooooooooo



you want unique ....keep the stock light and clocks ...these along with the tank ,panels and tail piece are the 1100ETs identity. Everyone seems to be doing the round headlight thing which to me doesnt work....this bike has big square lines keep em that way...


just my 5 cents

I know, I know....I think about that all the time. ha ha The front plastic bucket is very unique how it wraps the light and up onto the guage console. Long way to go before that, so time will tell.

[old_skool]

Hope your project keeps going, I know what you mean as far as running out of money and steam sometimes in the middle of a project, mine started last Sept/Nov and had it running briefly, now it's apart again, after you get it running and do a shake down, you may have to do the same, while you have it apart, I reccomend going throught the entire front end now, bearings, races etc, easier than tearing it apart again, mine should be back together in another week or so, drop me a pm of where you live, maybe I'll pop in and check in your progress if you want. I used to live in Clevelands west side.

[loud et]

Hope your project keeps going, I know what you mean as far as running out of money and steam sometimes in the middle of a project, mine started last Sept/Nov and had it running briefly, now it's apart again, after you get it running and do a shake down, you may have to do the same, while you have it apart, I reccomend going throught the entire front end now, bearings, races etc, easier than tearing it apart again, mine should be back together in another week or so, drop me a pm of where you live, maybe I'll pop in and check in your progress if you want. I used to live in Clevelands west side.

Heck yeah. Most of my engine gaskets were just ordered and are on the way, Carbs have been dipped and cleaned, have the new o rings. Gotta polish carb tops +bowls, and reassemble and bench sync. I have a long way to go. I am a half hour east of downtown CLE, If its a nice day for ridin, I would be glad to have ya stop out. I was off this project for 6 mos., ready to get it movin.

[old_skool]

That's one thing I didn't do yet, was tear the engine down and re-gasket, I actually don't have any of them leaking yet (knock on wood) I do see a spot occasionaly from the half round cam plugs. Should have done them when I did the adjustment. Next winter will be the frame off resto, I had too many things going this past winter, and had I got that detailed, I wouldn't be riding this summer. I'd reallty like to find a 1100G shafty for my next project, just picked up a non-titled 850 to play with, will mostly be just disassembling and shelving parts, great low mileage engine for a future build.

[loud et]

So I am actually getting back on this project.
Recently I
Disassembled head, cleaned/painted it.
Lapped valves, installed new valve seals/reassembled.
Honed cylinders, installed new rings/circlips.
Reinstalled cams/did timing.
New oem base and head gasket.
Torqued head down with new copper washers and o rings (on head nuts)
Did valve check. They are all right on to my disbelief.
Today I put in the nicer condition 81 EX harness from e bay and started wiring. (sorry Old_School, I could not wait)
Got half moons, exhaust crush gaskets, and exhaust wrap in the mail today, I am wrapping the exhaust because although its a Kirker 4-1, its sort of beat up and this bike will be mostly stock although will have its own flair.
Waiting on stainless bolt kit , (could not help myself, as there have been a lot of inexperienced hands using wrenches on this bike...lots of boogered up/mismatched/stripped screws. I have some helicoil stuff that should repair most of it.
My friend Lisa is makin me a custom leather seat. The original seat foam is mangled up pretty bad but she is gonna salvage the original shape and make me a nice 2 tone leather cover.
I have 2 burned up stators, so that will be one of the biggest purchases I have to make yet....I also have a box of R/R's, (please Lord let one of them be good)
Thankfully my carbs have already been properly (by me) cleaned/rebuilt according to the site here, so they are ready to pop in.
Also have APE pods coming.
This was a beater bike when I got it for 350$, and pretty chopped up by the PO/PO's, not frame wise, but mechanically and wiring.
I will be tryin gto keep a nice flow of pictures as I start to FINALLY put this Grand Pappy to the crotch rocket back together.

[7981GS]

I'd reallty like to find a 1100G shafty for my next project,

I never saw this post.

Eric

[loud et]

Really getting there now.

After a long break, I am doing well on my project. Note to other noobs like me, Honing cylinders and lapping valves , replacing valve seals and reinstalling cams and doing the timing is no big deal at all. As long as when you are doing the timing you dont use the T 2-3 mark, INSTEAD of the 1-4T. Just a couple pics
Lapping valves and honed cylinders on 16v head

[loud et]

The engine is completely resassembled, minus stator cover and sprocket cover. I used VHT Aluminum paint and for an amatuer, I think it looks great. The frame is a metallic bronze color. The exhaust is an old Kerker 4-1 that is quite banged up and ugly so I used this header wrap to hide the ugly, plus I wanted a different look for my bike. The header wrap looks totally awesome imo.
I still have to make an end cap for the exhaust. (missing)
I also used studs in the block for the exhaust . I had one that was stripped so I helicoiled it and hope thats the end of that nonsense.




Originally I was going to go for a vintage racer look with a big number plate and all...gonna pass on all that , but still have a few mods in mind.

[loud et]

First time out of the garage in a year!

I bled the brakes today, am sure I will need to do the fronts again.
I bench synced the carbs just now, will install them soon. I am waiting on a stator, and have a few wiring issues to figure out. The original harness was hacked/burned so I got one from an 81 and there are a few minor differences that have me stuck for a moment.
I am getting a custom leather seat cover made and am making my own side covers. The bike came with the orange paint already done, that is what set me on the path of a unique/ mild custom job.If it had been closer to stock ,I would have gone that path.
I am happy with the way things are looking.

[7981GS]

I probably have some stock covers that would need some sanding and painting if you need them.

eric

[GateKeeper]

did you spray down the header wrap with the special silicone spray they have, to protect the wrap and make it waterproof ?

http://www.designengineering.com/category/catalog/design-engineering-inc/exhaust-wraps-accessories/ht-silicone-coating

.

[loud et]

did you spray down the header wrap with the special silicone spray they have, to protect the wrap and make it waterproof ?

http://www.designengineering.com/category/catalog/design-engineering-inc/exhaust-wraps-accessories/ht-silicone-coating

.

No, I have not gotten that far. I have seen that stuff before. I think I have what is similar to their Titanium wrap, and the spray is not recommended for that.
Who knows what I will do. lol I am just winging it. Thanks for the pointer tho

[loud et]

Last night before I buttoned up my carbs, I recorded all my jet sizes so I can make the proper adjustments if it's not running right. It will have pod and a 4 into 1.
I did the bench sync and the float height adjustment.
I look forward to installing them with my new intake boots tonight.
I will also make a bracket to support the rear of the carbs since there is no air box to take the weight.

[loud et]

Plenty more to go before she is on the road, however, carbs are mounted. I used a couple "special" intake boot clamps till I get a couple.
Ape pods, wrapped my baffle with #4 steel wool and used some stainless zip ties to keep it in place. The baffle was naked before.
I actually fired it up this evening. It started easily with a little choke. Once the fuel got through the system it starts back up nicely. There is some popping. Not sure about the idle being stable yet, it hardly got to warm up, so once my gas tank is on tomorrow, with the new petcock, I will set up a fan and get it running a bit longer to see how it goes.
I am very happy, as I , an inexperienced engine mechanic have got this bike running. There was major smoke out of the tailpipe when I got it, and even after a fresh re ring and rebuild, I did not have any smoke on firing it up.
Here is a poor quality video.
More to follow soon as I begin wrapping up the finishing things on this bike.

[Tech73]

Sounds good!