New GS1100 G Restoration Project. Rebuilding my Dad's bike

[robzombie82gs1100]

Looking good. Keep up the hard work.

[6pkrunner]

Looks a lot nicer. A ton of crud comes off of them, doesn't it?

[wedoo2]

These projects are like having little victories every day. Too bad that when I tell someone that "I got my brake calipers rebuilt and mounted today" they just don't seem to get it.

[londonboards]

wedoo2 I know exactly what you mean. Getting the engine out of the frame was a massive victory for me and it took great effort, ingenuity, mangement and preparation. But to someone who has never been there it just seems like a regular occurance. Just as well we have this forum to share our victories with like minded geeks.

Greetings

[SqDancerLynn1]

You had the secondary gear out ! Don't forget to replace the big O ring before putting it back in the frame

[londonboards]

SqDancerLynn1 thanks for that. I might have been tempted to use the old one. There is also a metal gasket (type thingy). Do you think I will need to replace that. I don't know what it does.

I am thinking that to get the engine casings polished up (and possibly painted) I am going to need to split the engine apart so ending up with 100% strip and rebuild. I have known this engine since the day it was purchased (1985) so I know there is nothing wrong down there. Am I opening a can of worms stripping it down unecessarily to the very casings? Or do you think I can restore the casings without splitting them?



Greetings

[Biggie]

I've seen a few builds where they just seal the engine up (sparkplug holes, intake and exhaust holes) and mediablast the engine in one part. I don't think you have to polish much after that, just paint it. In my opinion, i would clean the hell out of the casings with a wirebrush mounted on a powerdrill without separating them and paint the whole engine in one part. i usually use abrasive wheels like these: http://www.toolstation.com/shop/Powe.../sd1920/p10332

They work very well and don't damage the aluminum casings. Just buy a lot of them because they wear out pretty fast (i use about 10 wheels for one engine, depending the level of corrosion). I use the 3M brand, they are the best kind i've used in the past years, but they are expensive.

[psyguy]

That metal thingy is not a gasket but a spacer (or several of them of varying thickness). They are used on secondary gears to get the right level of engagement between the gears. Mine actually have too much slack in them so there's a "clunk" each time you accelerate after a deceleration. This situation adds to the wear on the gears as well. If the gears are too tight together that promotes again (expensive) premature wear.

I don't know what the specs are for the setup, perhaps someone else does?

But each engine has an individual setup as the tolerances are very small.

[Good Times]

If you don't have to split the cases then I wouldn't. I got mine looking pretty decent while it was all in a lump. Painted the motor and polished the covers.

[londonboards]

Day 124 New Parts Arrive Old Parts Come Off

Unless you are actually involved in a rebuild / restoration project like this, you will simply have no idea how exciting it can be to get a parcel of parts.

See my blog entry: My GS1100G Blog - New Parts Arrive



These new carb boots are simply beautiful. Just a bit of metal and rubber to some but not to me.

I have also been taking off a few more bits; the frame is nearly completely stripped now apart from the forks.







Greetings

[6pkrunner]

....you will simply have no idea how exciting it can be to get a parcel of parts.

Just like Christmas every time a parcel arrives. I know, believe me I know. Those that aren't into it, look at you like you've got three heads getting all worked up over bike bits. I pity them.

[londonboards]

Indeed 6pkrunner I can't remember feeling like that since I was a child opening my Christmas presents. There was perhaps one other occasion when I got my first new laptop by courier delivery. Don't you love the smell of new laptop first thing in the morning? That was back in mid '90s:



Greetings

[6pkrunner]

The magic does indeed exist!

[Big T]

If you do decide to go for the full strip down for paint prep, I recommend getting it bead blasted, followed by vapor blasting

The bead blasting will remove any paint and corrosion, the vapor blasting will smooth out the finish and flush the abrasive media out of the orifices. The vapor blasting media washes off with water, especially if it is done immediately after blasting

I have a friend that has both blast cabinets and he lets me drop in and use them. The vapor blasting works great if the finish is just worn. The bead blasting would be needed for your cases.

I'd recommend a full strip down just because you'll probably need to replace the base gasket and other seals, so you might as well make the motor fresh now rather than after you get it done

[Charlie G]

Parts arriving are like presents. It looked like you got a bit of snow last week. This week is the first in a month that it's starting to get above freezing.

cg