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

[tatu]

Hamshire - yes indeed. I was just trying to get the top yoke bearing shell in and there is quite a lot of paint about. I scraped it out (Scotchbrite) but it still went in crooked and is now stuck. Guess I need a bigger hammer.

Greetings

Bring it round and lets have a look.

[londonboards]

Day 338 - Project Update and New Bike Purchase

Nearly done the year since I started this rebuild so here's a little progress report:

I am, still in my mind, no where near the half way stage. Given my rate of progress (determined by the availability of time AND money) and what I have achieved so far, I estimate completion now is likely to be for summer 2015 (I originally thought summer 2014).

At this point I have the frame (and 22 other pieces) powder coated and ready to go. One fork lower tube refurbished and lacquered. Most of my replacement parts in stock. Carburetors completely refurbished (vapour blasted and cleaned) and awaiting assembly with cadmium plated parts. Forks stanchions have been re-chromed. Not much else really. I have done some work on the wheels but that's it.

So the "to do" list is for ever: engine clean, paint and top end overhaul (not decided on that at the moment), wiring harness refurbishment and then re-assembly of the whole thing. Oh I also need to get the paintwork done on the tank, tail, side panels and front mudguard.

So in order to relieve the frustration of being a born-again biker and not having a bike on the road, I went a hunting for a bike I could use this summer to get me back into the swing of things. I have not ridden my own bike on the road for at least 15 years.

I came across this guy: GS1100G For Sale



I will be picking it up in the next few weeks and hope to get it on the road by the end of August. I will ride it and mix and match the parts with my bike (although this "new" one is a 1982 model and mine is a 1983). I am hoping the seat pan is in good nick and that the exhaust (not pretty on this bike) is serviceable. I will post more pics of it when I get it home.

Greetings

[Charlie G]

I don't know for certian that your "new" bike is priced right or not, but I would have expected it to cost much more than you paid for it. Congratulations!

cg

[Agemax]

"sold as seen", only runs on 3 cylinders but just needs carbs cleaning.......

hmmmmm where have i heard that before!

[londonboards]

Agemax - hhhmmm. Tell me more. Actually, if it's really bad news I'm not sure I want to know now the deal is done. If it really is a bummer, I can re-list it in few weeks. I would not expect to lose much on it.

Oh go on tell me the bad news.

Greetings

[hampshirehog]

I bet it'll just need the valve clearances checking, carbs cleaning, oil and filter and new plugs, new tyres, fuel tap and hoses, brake refurb, electrics sorting.....only one way to find out!

[SVSooke]

I picked up a 81 650E for very few $$ years ago because it was running on 3 cylinders,it need a petcock.Got my 85 750EF for very few $$ because it wouldn't start,it needed a petcock.See a connection?

[londonboards]

SVSooke - I can use the one from my other bike to test it. Thanks for that tip.

Greetings

[Paul]

Agemax - hhhmmm. Tell me more. Actually, if it's really bad news I'm not sure I want to know now the deal is done. If it really is a bummer, I can re-list it in few weeks. I would not expect to lose much on it.

Oh go on tell me the bad news.

Greetings

I'd have given you the same money for it for I was going to buy another, I think you did ok! And as already said valves, tyres etc... it should be OK.... and once it's ridden for a year and has some history you could sell it with tax and text for £1300+ I think

[althomas101]

I picked up a 81 650E for very few $$ years ago because it was running on 3 cylinders,it need a petcock.Got my 85 750EF for very few $$ because it wouldn't start,it needed a petcock.See a connection?

Yea I got my GS1000 super cheap because it only ran on 2 cylinders, one from clogged pilot jet, and the other from a bad petcock. Also it smoked from the rings sticking, the guy though the engine was shot.

[londonboards]

Installing Head Races and Swing Arm Bearings

The rebuild has begun. The tables have turned. I have been distracted of late because I bought another GS1100G and I have been getting that one road ready so that I can start riding again. (See: GS1100G - Road Runner Thread). But here we go. Head races are going in. I did not have much luck on my own (first one started going in sideways) so I went to get some expert help from a guy with a lot of experience and lots of tools.

See: My GS1100G Blog - Installing Head Races

First clean up the inner surfaces:



Then use a 10 ton press.



Then onto the swing arm. We used to other half as a bolster.



In you go:



The rebuild has started!

Greetings

[ron bayless]

I dont know what step you are on now.I hope you dont stop posting.I would have given up long ago if i had started with the mess you had.But it was your dad's which makes it more important.great job.I know now you can fully know how crappy japanese screws and bolts were.

[londonboards]

Ron - Don't worry I am still much involved in the project. I just got a little diverted by wanting to do some riding so I bought another GS1100G to get on the road. See: My Road Runner Project Thread.

Greetings

[londonboards]

Day 511 - Preparing Streering Head for Reassembly

It has been some months since my last post. But I have finally started back into the restoration of this fabulous bike.

I have spent quite a bit of time over the last 3 months getting my other GS1100G on the road so that I at least had a Road Runner bike to drive whilst this one was being restored. I estimate that I still need another 18 months at least to finish this bike and that was too long to go without having a bike on the road. See My Suzuki GS1100G Road Runner thread and My Suzuki GS1100G Road Runner Blog. So I now have 2 of these beasts.

I still have to do a clean up of the engine, probably with a top end overhaul, a repaint of the engine and a wiring harness overhaul. But in order that I can see some progress, I am going to put some stuff back on the frame.

So the next job was to prepare the steering head parts for reassembly. See My GS1100G Blog - Preparing Steering Head.

The steering head parts have been lovingly powder coated:







I needed to remove the masking tape and tap out the holes where the paint had got in and polish up the bolts:









and I need to find a way to get this bearing seated. But first I need to find the washer that is supposed to be underneath it:



Greetings

[tatu]

You might need to clean the paint from the yokes where the fork tubes fit, I believe you have some nicely redone ones? Test fit them, I suspect they will be tight.
If you knew someone with a press you could shove that bearing down using a long tube, give it a smear of grease or oil to help it slip down. If you decide to pound it down using a tube and hammer remember you might spoil the powder coat on the underside of the yoke.