83 GSX1100ES, "worn-out-edition"

[Spiff]

Maybebaby

I've bought some oxford heated grips, these are the best and with the new smart controller it's super easy to connect. It just hooks up to your battery and you're done




Another thing I'm gonna buy to increase comfort is heated seat pads.

[russr33]

Good luck on the rebuild Spiff. I've always liked that color scheme on the ES; we didn't get that option in the US just the blue/white scheme. Should be a fun thread to watch. I used to have an ES with the Lockhart fairing which is similar to the look you will achieve (somewhat).

[Charlie G]

Good luck on the rebuild Spiff. I've always liked that color scheme on the ES; we didn't get that option in the US just the blue/white scheme. Should be a fun thread to watch. I used to have an ES with the Lockhart fairing which is similar to the look you will achieve (somewhat).

My favorite color scheme

cg

[Spiff]

Yeah that's a nice color scheme ;-)

[Spiff]

Ok, so I tried fixing the cracked stator cover using hts-2000 aluminium brazing rods but that turned out to be just load of crap! Cover was still leaking, but I wasn't quite ready to give in and buy a new stator cover just yet!
Enter Sugru:



This stuff is like play-doh, only it hardens when exposed to air to form a hard siliconrubber. It adheres to most anything, withstands temperatures from -50 to a 180degrees C. so I figured why not give it a shot!

Was alot of work grinding away the hts-2000 braze, that stuff probably contains a whole lot of Zn, hard as nails! But it came of eventually and again I V'ed out the crack. Rubbed it with som 80 grit and degreased it and washed thoroughly with alcohol! Sugru doesn't adhere well if there is the tiniest residue of oil left...ask me how I know
I applied one pack and pressed it firmly in and around the groove and smoothed it out:


A test after it had hardened to see if it sealed, it stood like this for a week without showing any signs of sweating or leaking on the outside of the cover


I haven't mounted it yet since I need to get, or make a new gasket for the cover. I guess then we'll see just how good this stuff is...
Here you can see the crack in the middle of the picture, just a hairline crack, but still more then enough to drip badly.

[eil]

Uh, I'm reasonably certain that this is not the right material for this repair. Even if you don't quite hit its max temperature, do you know how well it stands up to worn-out contaminated engine oil? Every use of Sugru that I've seen is lightweight stuff like holding things together or adding grips to pencils and cell phones, things like that. Not inside an engine. If it gums up and gets loose, it's going to plug an oil gallery and then the fun begins.

J.B. Weld or one of its many knock-offs is a much better choice, is known to work well for these kinds of repairs, and is likely cheaper than Sugru.

[Spiff]

Unfortunately you are right it seems that stuff doesn't like oil to much and CAN detoriate over time i found out after some searching.
Fortunately it's easy to remove, and I replaced it with some 2k epoxy. JB weld isn't readily available here....

I did get some other work done these days, I have adjusted the valves.

I replaced the fork seals and found out my anti dive units are seized.
I replaced the old fork oil (if it could be called oil....) and changed brake fluid.
So now I have a working brakes front and rear
I also replaced the seat cover which was a real PITA 'cause it's a vinyl seat cover and vinyl doesn't stretch easily if any making it real hard to get a perfect fit on seats like this that angles up on the gas tank.
But I'm contempt with the result and tomorrow I'm gonna test ride it, I also swapped the rusty handlebars with the old ones from my GS.
I'll get some pictures of all of this but in the meantime all i have is the picture of the seat





Sent from my C6903 using Tapatalk

[Charlie G]

I understand too well the difficulty of install one of those vinyl seat covers. You've been busy.

cg

[Spiff]

Got a little bit more done last week, mounted the seat:



Also look at the pannier mount! shiny black right? Used the brake fluid i bled from the front brakes to get it back to how it once looked

GS handlebar



I also found some good use for that sugru stuff!
New mounting posts for the sidecovers, works a charm!



I've also adjusted valves, replaced valve cover gasket, stator cover gasket and I have picked off the carb rack for a strip and dip!

[GS1150Pilot]

Awesome resuscitation work!

[Spiff]

Tearing the carbs apart now! Almost destroyed the air screw but just managed to rescue it! Second carb wasn't any problem at all.... Will do the last two tomorrow.


Sprayed full of brake cleaner, then they will go in the ultarasonic bath.


The tub in the middle is where the removed carburettor parts where... dirty stuff...

[Spiff]

So after spending some time in the ultrasonic bath the already knackered paint just flaked of...



If I throw them in a bath of paint stripper or something like that, would I then need to re-clean the carbs again? I think I may?

[Rob S.]

Gorgeous so far!

I know it's cold up there in Norway, but is there any way I could convince you to stay with the stock fairing? I know it's just a "bikini", but you'll still have the heated grips and seat.

Any way you go, I'm sure she'll be great. Pics! Pics! And more pics!

[2BRacing]

What liquid did you use in the ultrasonic bath?

Just a heads up: do not leave the bodies in any aggressive solvent/material (eg paint stripper) for too long - it may affect the throttle shaft seals.

Well done on your progress so far!

[Spiff]

What liquid did you use in the ultrasonic bath?

Just a heads up: do not leave the bodies in any aggressive solvent/material (eg paint stripper) for too long - it may affect the throttle shaft seals.

Well done on your progress so far!

Dishwasher liquid. Like your simple green.