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

[londonboards]

Charlie - Indeed we have had snow for about a week and temperatures have been below about 3 deg C for the last couple of weeks. Our garages are not heated. They are freezing so I don't do any wrenching when it is like that.

I spend my time sifting through parts suppliers, talking to other GSers and getting my parts in.

Looking forward to a nice day to clear the garage out and start work again.

Greetings

[londonboards]

Day 161 More New Parts

It's cold and miserable around here (United Kingdom) so work on the bike has stopped for a while. But I have not been idle. I have been ordering parts and scouring eBay for bits and pieces. Here are some of the things I have got:



I bought 4 of these kits and they have 18 pieces in them including the needle jet and it's valve.

Also got these:



I was advised that mine were "goosed".

I have never been so excited opening parcels since I was a boy getting my Christmas presents.

Greetings

[londonboards]

Day 169 Carburetor Workbench

Before starting to strip the carbs, I needed a place to work.

See my My GS1100G Blog - Carburetor Workbench

[londonboards]

Day 169 Carburetor Strip Down (part 1)

Now I am all set up with my workbench, the task begins. More in depth descriptions and more photos here:

My GS1100G Blog - Carburetor Breakdown (part 1)

Some screws have washers and some don't.


Join tubes coming apart. New O rings here please.

Concoction on the choke activation rail.

This was the worst carb bowl. Ultrasonic here we come.

Main jet and washer. Slot on jet was like that when I opened it up. Installed like that in the factory. We have never had the bowls off before.

Needle jet from above.

Needle jet coming out.


Greetings

[Charlie G]

Ugly carbs!

[londonboards]

Charlie G Won't be for too long I hope.

Greetings

[Agemax]

mate, i have to disagree with that pic of the main jet, there is NO WAY that came like that from the factory. somebody has had a bad screwdriver attack on that at some point....

[londonboards]

Agemax - you are right. It's ridiculously damaged. Beggars belief really. The main jet must be the easiest one to put in and get out as it has a nice big slot and is easily accessed. Why would anyone have needed to apply so much force to it.

The only logical explanation is that the shop that serviced the bike (in Burlington, Ontario) must have, at some stage, needed to clean the carbs or change the jets. We have owned this bike since new and it has only ever been serviced by one shop in it's life and that would have been between 1984/5 and 1990. Since then it's been in my possession and not touched on the carb front.

The plot thickens.

Greetings

[Agemax]

Agemax - you are right. It's ridiculously damaged. Beggars belief really. The main jet must be the easiest one to put in and get out as it has a nice big slot and is easily accessed. Why would anyone have needed to apply so much force to it.

The only logical explanation is that the shop that serviced the bike (in Burlington, Ontario) must have, at some stage, needed to clean the carbs or change the jets. We have owned this bike since new and it has only ever been serviced by one shop in it's life and that would have been between 1984/5 and 1990. Since then it's been in my possession and not touched on the carb front.

The plot thickens.

Greetings

Damage like that is usually caused by using a badly fitting screwdriver, even more so if they are screwed in real tight. i would replace them or just give them a good dressing up with a small file. it shouldn't affect their performance.

[londonboards]

Day 170 More Main Jet Shananigans

Got all the main jets out now.

See My GS1100G Blog - Main Jet Shananigans

Who would have done this and why? Does the washer thickness affect the fuel/air mix?


And this looks pretty grim. Why did it need to be tightened so hard? I suppose "115" refers to size.


Greetings

[londonboards]

Day 175 Carb Breakdown (part 2)

Pulling the carbs apart now. Having the usual problems on the way. I had 2 stripped pilot jets, one stripped needle valve screw and a nearly stripped choke assembly nut.

See My GS1100G Blog - Carb Breakdown part 2

I start off by not breaking any of the float pin pegs using the suggested box spanner method.


But one of these had to have the Dremel treatment



Then I got all the needle valves out



And they don't seem to be in bad shape although I will be replacing them as a matter of course



Then it was choke assemblies which proved pretty difficult. It's hard trying to hold the carb assembly and apply enough pressure on the spanner to get them off. Some of my concoction helped.



Now I am wondering how to go about cleaning up these parts without taking the butterfly valves apart. It seems it is not recommended to take these apart.



Greetings

[londonboards]

Day 175 Pilot Jet Shananigans

These were the big problem. 2 came out easy. One after a bit of persuasion (and concoction) and the final one well ......

See My GS1100G Blog - Pilot Jet Shananigans

This is what we are talking about



and this was the one that needed persuasion. The head was already quite chewed up when I got to it



And this was the beast



and the tool I made to do it (full details on the blog link above)



Greetings

[hampshirehog]

I would take those butterfly valves apart and re-zinc the springs. The concern is when you reassemble that the screws on the valves work loose and head in to your engine. If you peen over the threaded end on reassembly you will eliminate that risk. I've done it many times and never had anything go AWOL.

Great close up photo of the needle valve. I reckon that one is worn out - though that might be the photo telling me that; in reality I doubt I could see that level of detail looking through a magnifying glass so would probably pass it as ok in my garage.

[londonboards]

I would take those butterfly valves apart and re-zinc the springs. The concern is when you reassemble that the screws on the valves work loose and head in to your engine. If you peen over the threaded end on reassembly you will eliminate that risk. I've done it many times and never had anything go AWOL.

Great close up photo of the needle valve. I reckon that one is worn out - though that might be the photo telling me that; in reality I doubt I could see that level of detail looking through a magnifying glass so would probably pass it as ok in my garage.

In which case I will have a go at taking them apart. I might as well since I have got this far.

The needle valves are marked rather than grooved or damaged but i will rebuild with new in any case.

Greetings

[psyguy]

I would take those butterfly valves apart and re-zinc the springs.

... and there's also o'rings on those buterfly shafts that you definitely want to replace!