GS1100G Road Runner Project

[Agemax]

that is why you have running issues. you have refitted the spark plugs upside down!

[londonboards]

Carburetor Clean and Rebuild

Ultrasonically cleaned them and rebuilt them with all new 'O' rings.

See My GS1100G Road Runner Blog - Carb Strip and Rebuild

Found this stuff in the needle valve filters:



Made sure all passageways were clear.







Checked out float heights. They all needed minor adjustment.













Greetings

[londonboards]

Cam Cover and Airbox Cleanup

Cam cover was a mess of silver paint (so is the engine!) but whilst it was off I stripped it all off.

See: My GS1100G Road Runner - Cam Cover Clean UP







And I also cleaned out the airbox and installed a new air filter.



Greetings

[londonboards]

Re-Installed Carburetors

I squeezed the carbs in using planks of wood.

See: My GS1100G Road Runner Project - Re-Instal Carburetors

You need big pieces of wood!



Nearly did it like this:



But then ended up like this:





Then I discovered the choke assembly return spring was in between the wrong carbs. Should be between carbs 3 and 4!



So they all came off again. Then when I put them on again I discovered the intake boots were upside down so, as you can see, the carbs did not fit into the airbox boots. Take them off again and fix.



Greetings

[Nessism]

Nice photos!

Great job.

Keep going...

[londonboards]

First Start Up After Carb Rebuild

Well she started after the 2nd jab even though it was only on 2 cylinders at first:

https://www.youtube.com/watch?v=BcN2MbdMcgk

Greetings

[Charlie G]

Nice to get an update and hear the engine roar. Cheers!

cg

[londonboards]

Yeah good spot Age. I thought that it would be a good thing to do to stop anything falling down the plug holes. But rookie mistake (no. 32) is that when you turn the engine over to line up the cam lobes, the piston hits the upside down sparkplug. This bends the sparkplug connector and damages (marks) the piston.

Door and knob springs to mind!

Greetings

[londonboards]

Nessism - Ha ha. I had not realised I was drinking a bottle of First Brew for my first start up!

Greetings

[londonboards]

New Cam Gasket and D Plugs

So after doing the valve clearances and to try and stop the oil leak, I get a new cam gasket and D plugs.

See: My GS1100 G Road Runner Blog - Cam Gasket





Check all the surfaces.





and put it all back together will some gasket compound around the oil leak area. That did the trick.

[londonboards]

Exhaust Bolts

I wanted to see what was going on with this selection of exhaust bolts the PO has installed.

See: My GS1100G Road Runner Project - Exhaust Bolts

This is what I took out:



See the grey sealing cement which came out. Some one was trying to plug the holes. No wonder it sounds like it's blowing!



Compare this to the set I took out of my other GS1100:



You can see the problem is that the bolts are only biting on the last few threads. They should be seated further down the bolt holes. Why is this .....



..... extra large flange spacers don't allow the bolts to seat properly.



These and the bolts are going to have to be replaced at some stage.

[londonboards]

Why Don't My Brakes Work?

I thought I should have a little investigation to see why the bike was not stopping:









And look at the carnage a PO had inflicted on these poor pistons:





So a good clean up, new rubbers and lube and away we go.



Greetings

[Nessism]

Missed this before...

You are measuring to the wrong spot on the float. You need to measure to the bottom of the step, not the top.

Doing a great job overall. Love the photos.

[hampshirehog]

Richard, the RSPCA will be after you - turfing all those animals living in your brakes out of their home......

Are the pistons salvageable? You can tidy up the ends - as long as you don't take off too much material. It's gouges and pits on the walls that turn them into fishing weights.

[eil]

Those calipers... wow! What kind of a PO uses corn meal instead of brake fluid?