1982 GS1100EZ Phase II

[Guest]

My project is all over the place in the "Technical" forums, so here's an overview.

Phase II summary:

1. 1984 GS1150 motor.
2. 1995 GSX600 Katana oil cooler.
3. Mikuni RS38 Race carbs.
4. K&N pod air filters.
5. 1992 GSF400 Bandit gauges.
6. 2003 GSXR750 handlebar controls.
7. Dyna 2000 ignition system with wires and coils.
8. SSPB Solid State Power Box.
9. Series Regulator Rectifier*.

As the bike sat Summer 2013.


1984 GS1150 stock motor.


Motor installed, Bandit cluster mounted.


Dyna 2000 mounted, Battery raised 3.5".


1995 GSX600 Katana Oil Cooler installed.


Adapters fabricated. 16mm GSX banjos to 14mm GS oil ports.

[CivilRock]

continued...

Diagnosed and fixed upshift problem.


Deleted the TSCU. Deleted the CPCU. Deleted all the redundant wiring. Added a SSPB, Added a Series R/R (not pictured yet)




Added Mikuni RS38 carbs with K&N pods.


1992 GSF400 Bandit Instrument cluster.
2003 GSXR750 Handlebar Controls.


As it sits just now at my office after a great morning commute!

[harley10]

What do you think of its power compared to before with 1150 and new carbs,Brian

[CivilRock]

What do you think of its power compared to before with 1150 and new carbs,Brian

It's hard to tell riding in traffic.

Plus, I had the 1100 set up perfectly. This one needs some time to break-in, and for me to get the carbs dialed in. I have 20 miles on it total, and the motor was sitting around for at least 5 years. Only 6,600 on it, so it's had some years of non-use.

Larry Cook (Drag Legend and family friend helping me with advice) told me to ride it for a while before we do some tweaks on the settings.

It's got a huge bog in the needle jetting right now and it's a little sticky off idle. I also think the 1150 gearing is way taller. I might have to drop a tooth in the front, or go up a few in the back.

I can tell there's more horses there. The true test will be on the strip. I've just got to beat an 11.5 at 118.

-Kevin

[harley10]

Kevin it looks good , I look forward to seeing how it does time wise!!

[CivilRock]

Ok, I got on it a little more on the way home. Then I left my laptop at my house and went out and gave it the beans.

I know when I went to the track last summer that was the only time I had ever got the front wheel off the ground.

Now it will do it on command, or in a roll-on. ...in 1st gear anyway.

There's definitely more power there. I just need to tidy it up a little. It's already getting better as I ride it.

=Kevin

[Badooka]

Amazing that little motor can cause so much happiness and utter despair.
Nice project- like the gauges!

Also-if you look quickly at the second to last photo- looks like you have that 5 gallon bucket mounted to your handle bars! LoL one helluva reservoir there!!!!!!!!!!

[Battleship62]

Very Cool

Digging what you're doing with this bike. I read and enjoyed your GS1100EZ story on your Civil Rock Racing web page. Looking forward to your phase III.

[CivilRock]

Amazing that little motor can cause so much happiness and utter despair.
Nice project- like the gauges!

Also-if you look quickly at the second to last photo- looks like you have that 5 gallon bucket mounted to your handle bars! LoL one helluva reservoir there!!!!!!!!!!

No optical illusion. I carry 5 gallons of brake fluid on the bars. All the cool kids are doing it.

No doubt on the dispair. I was sure I bought a basket case motor. After I "tuned" the shifter spring, it's smooth as butter now.

The coolest thing right now about it is the obscene sounds that it makes at the carbs. You can hear each huff the motor makes as its pulling air past the clacking flat slides at idle. I'm going to have to figure out how to record the noise somehow.

-Kevin

[kimjay]

Awesome bike, but i gotta ask, you commute on bald tires?

[Rob S.]

"Adapters fabricated"

I can't tell you how much time I've spent staring at your photo of the oil line bolt fabrication you've done - admiring your work, and dreaming of learning to weld someday myself.

One question - you went with a 600 Katana oil cooler. Is it bigger than a stock 1150 cooler?

I love your bike and your thread. I ride a stock (except for exhaust & pods) 1100EZ, so I get vicarious thrills from yours.

[CivilRock]

Awesome bike, but i gotta ask, you commute on bald tires?

They're not quite bald, but they look like it, don't they? They're DOT race tires, and I have an endless supply of them. I get them for free or $20/ea and they last 3-4k miles. The sides are usually shagged, but the middles are like new. And that's the part that I use 85% of the time. They're the exact same composition as full on slicks with minimal siping so they're DOT legal for supersport classes.

One question - you went with a 600 Katana oil cooler. Is it bigger than a stock 1150 cooler?

Rob,
I took metal shop in high school and loved it. I bought my MIG welder at Home Depot about 10 years ago for $400, and a racing buddy gave me his Mini-Lathe for FREE if I could figure out how to make some spacers for him. I just like playing around with this stuff in the garage, and I'm amazed at all the uses I've come up with to use both. I use both those tools at least 2-3 times a month. The welding part was easy, but I'm pretty proud of the idea, and my lathe work. So thanks.

I don't have an 1150 cooler to measure, but I would guess that this one is about 3 times bigger than the 1150. I was just trying to find something that would work by looking at pictures on Ebay and then looking up corresponding parts with online microfiche for the banjo fittings. This one was $29 shipped with the cooler lines, and every 1150 I looked at was around $200. To be honest, I think the 600 oil cooler is a bit overkill. I'm glad I didn't go for the 750 unit, it's even bigger. Hopefully I'll be glad I did it once I bump the power up to 160HP. The power builders seem to agree that more cooling is better.

-Kevin

Here's some more pics during the fabrication of those adapters. Oh, and I actually didn't expect this to work. I wasn't sure I could drill into the bolts cleanly or centered. I was pleasantly surprised with the results.

I started with a small centering bit, then worked my way up until I got as far as I thought would be safe.


Then I used an even bigger bit to "neck" it up closer to the 16mm nut ID, if you look closely, it's not exactly centered on the bolt head:


But the important end was perfectly centered, so I was happy.


Then I just welded them together.


If you look at the far port, you can see that once I add the copper washer it's still not going to work. The bored out 14mm bolt is too long. I ended up taking off about 7mm of the end and carefully cleaned up the threads. While I had them on the bench I filed down the welds and gave them some paint. I'll have to take another picture of the final product.

[CivilRock]

Rob S., Here's how the adapters look in their final resting place. Probably should have let the paint dry a little longer before I installed them. Getting up close to the bike in the sunshine (it's been absent for a while now) I realize how much this bike needs a detail. I haven't even cleaned it in a year. She's not going to win any show awards, but I still love her.



If I can sell enough of my old parts for a new seat I'm going to do it. Then I need to get to polishing. All my polish work has faded over the last 9 years. It's time to freshen her up a bit.

[posplayr]

If I can sell enough of my old parts for a new seat I'm going to do it. Then I need to get to polishing. All my polish work has faded over the last 9 years. It's time to freshen her up a bit.

Black paint really likes to be kept spotless, but with a buff and new seat she should look quite presentable, that is if you can even focus on paint with those RS38's rattling.

[CivilRock]

One question - you went with a 600 Katana oil cooler. Is it bigger than a stock 1150 cooler?

The GSX600 cooler is 16" wide, 5" tall with another 2" on top for the connectors/banjos, and an inch thick.

I'm curious about the stock gs1150 dimensions myself.

Kevin