Another Aussie GS rebuild - GS1100G

[JimmyR]

Not entirely sure Pete. I reckon there's not too much more to do before powdercoat though. I have to drill some mounting holes for the rear indicators and mudguard. I also have to sort out a smaller rear braked fluid reservior because I couldn't stand the plastic jar in the triangle under the seat. I can live with the massive master cylinder but the nivea jar had to go. I have room for a narrower (rectangular?) reservior under the seat beside the mudguard but the stock jar doesn't fit.

I should have taken a pic of it but forgot - you can see in the last pic that behind the rear shock there is a bit of frame hanging below the seat loop. That's where we capped off the frame support and welded a flat piece to bolt the indicators to. It's all sort of blended in but I'll take a pic soon once the indicators are mounted.

So I'm hoping to get the frame to powder coat this week. It really will make a HUGE difference to how the bike looks. And tonight I have been checking out my new RS36 carbs, making sure that they have the right jets, attaching fuel lines, etc. They are extremely compact!

Tomorrow I must finish the front fender mount too. I want to get it powdercoated the same texture black as the frame and swingarm.

[Charlie G]

The job on the seat is certainly well done!

cg

[pete]

Good stuff Jimmy, fingers crossed you make it this week!

[Johnny Drummond]

frame loop

Hi Jimmy,the loop looks great!, I like the way you added that little tab where your addition joins the standard frame,it looks like it should be there to any untutored person(you'll have great fun at classic shows listening to people arguing if all 1100G's were like that)as I found before I changed my GS1000 engine and had no badges to identify the model for the GSX engine.The best ever overheard was "bloody hell,its not often you see 2 GS750's parked together anymore".The owner of the very highly restored GS750 looked over these "experts" heads and mouthed "w****rs" at me, I had to walk away I was laughing so hard!.Anyway it looks like you are going to have a fantastic bike when you are done-how about some pictures of it in the sun as I've forgotten what it looks like.Johnny

[bigboresuzuki]

Hi Jimmy,just finished reading your thread and loving the build so far.Was fortunate enough to go on the GS ride with Pete and the boys back in February.South east Queensland.Hope you can hook up with some W.A boys for a GS ride.Makes this site become a reality.Did a 4WD course north of Perth for a RioTinto induction.Some nice winding roads up there if you can stay off the gravel.
Good luck and enjoy the new carbs.Crisp and responsive.Whooaa. Cheers Mark

[JimmyR]

Ok crap photo and it doesn't look very pretty here - but it works really well! this is the thing that the seat hooks under to stay on the bike.

[JimmyR]

Well it's strip-down time! For the bike. Not me. That would be gross and I'm not posting pictures of that.

I have the engine sitting on a pile of bricks, still inside the frame and protected from harm by a jarrah plank. Tomorrow I will see if my favourite steel shop is open and buy two lengths of steel rod to run through the frame bolt holes to make lifting easier. Nothing is actually holding the engine in the frame but I can't find a way to get a grip on it to move it. These 1100 engines are bloody massive. I reckon a couple of steel rods will make lifting it much easier and be a quick job for two blokes. I have my bike jack standing by next to the frame ready for the engine.

So if all goes well the frame and a bunch of other parts will be at the powder coaters next monday.

[Good Times]

The steel rod method will be S.O.P. for me. Much easier, for me anyway.

[JimmyR]

Yeah I don't know how else people do it! I hope the steel place is open.

BTW Johnny I forgot to mention that I love your stories. I wish I could buy you a pint or two of the black stuff and talk bikes...

[pete]

Hi Jimmy,just finished reading your thread and loving the build so far.Was fortunate enough to go on the GS ride with Pete and the boys back in February.South east Queensland.Hope you can hook up with some W.A boys for a GS ride.Makes this site become a reality.Did a 4WD course north of Perth for a RioTinto induction.Some nice winding roads up there if you can stay off the gravel.
Good luck and enjoy the new carbs.Crisp and responsive.Whooaa. Cheers Mark

Yeah that was great stuff Mark, can't wait for the next one! I'm trying to squeeze in the Kat forum run next weekend but not sure on that just yet...

Well it's strip-down time! For the bike. Not me. That would be gross and I'm not posting pictures of that.

I have the engine sitting on a pile of bricks, still inside the frame and protected from harm by a jarrah plank. Tomorrow I will see if my favourite steel shop is open and buy two lengths of steel rod to run through the frame bolt holes to make lifting easier. Nothing is actually holding the engine in the frame but I can't find a way to get a grip on it to move it. These 1100 engines are bloody massive. I reckon a couple of steel rods will make lifting it much easier and be a quick job for two blokes. I have my bike jack standing by next to the frame ready for the engine.

So if all goes well the frame and a bunch of other parts will be at the powder coaters next monday.

Thanks for *not* sharing a personal strip down Jimmy, definitely something I don't need to hear...

That seat loop is similar to how my stock 450 seat latches on at the front, and yes very simple and effective. How are you actually anchoring it to the frame though? I was able to keep the stock duck tail frame and reuse it with the tail piece I made so I've been able to retain the stock seat lock which was my aim.

Can't wait to see her once the frame's powdercoated, don't forget to mask all those threads!

[JimmyR]

Engine is out! I got a 1.8m length of 10mm rod, cut it in half and slotted it into the engine bolt holes and with the help of my gracious neighbour got it out fairly painlessly. The steel rod made it soooo much easier than it could have been. Bent the front rod quite a bit! I'll take pics after a bit.

My current neighbour is a really top bloke who also rides a bit. He has a Honda 400 V-something sportsbike. He's also pretty handy himself - builds a lot of furniture from found timber, that sort of thing. So cool to have people like that living next door. I'm very lucky.

[JimmyR]

Pics - frame ready for powdercoat and all the other bits I will take as well tomorrow:





Here you can see the steel rods which acted as handles to get the engine out. They bent a bit!

[JimmyR]

And here you can just make out the amount of crap I have had to deal with - that crud was all over the engine:

[pete]

Awesome Jimmy, can't wait to see how they turn out! How long til you get 'em back?

What's the plan for the engine? Just a good clean or will you be doing any paint/polish?

[Good Times]

You will love the transformation after powder coat!

My Allthread rods looked the same way after putting the motor in.

Time to get scrubbin' on that motor. Fun stuff!

One more step toward perfection.