82 GS1100E Mr Turbo Rebuild

[oldGSfan]

Morning... haha! Thankfully the bourbon was unscathed.

Oh boy.... a bourbon accident. I had a wine accident once while working on the bike. These days I wait until the tools are put down for the night.

The bike is coming along nicely.

[dorkburger]

Oh boy.... a bourbon accident. I had a wine accident once while working on the bike. These days I wait until the tools are put down for the night.

The bike is coming along nicely.

[oldGSfan]

The bar is stock from diagrams & eBay parts I've seen. The oil lines are OK, they tuck in fine and must have worked given where and how it was ridden. I will keep as is.

I'm finding little special touches like shorter front turn signal stalks, modified brake arm that's cut away to allow a wider tire. Pretty cool time capsule of stuff I probably would have done way back when if I had any money.

You want to be careful with those oversized oil coolers. You don't need some a-hole thinking it's a liquid cooled bike! And it's kind of a shame it doesn't take advantage of the two ports Suzuki designed into the engine.

What is that silver bar going between the two cams at the base of the spark plug wire? It's almost like a top end oiler, only on the inside. I don't see that on my bike.

[Rob S.]

You want to be careful with those oversized oil coolers. You don't need some a-hole thinking it's a liquid cooled bike! And it's kind of a shame it doesn't take advantage of the two ports Suzuki designed into the engine.

What is that silver bar going between the two cams at the base of the spark plug wire? It's almost like a top end oiler, only on the inside. I don't see that on my bike.

[oldGSfan]

Been pondering direction on some stuff as I get to the final assembly, so some ramblings here.

The oil cooler is huge! It's an 18 row, 12" x 6" Earl's with the feed coming from the filter cover. I don't know why that was used rather than running lines from the two bolts on the front of the engine, but the cover is custom engineered (Lockhart or Kerker perhaps) so I suppose there's a decent reason. The cooler doesn't hinder the steering or suspension and it's sort of badass so I'll mount it. There's no thermostat, maybe good to add? I won't be riding WFO across a salt flat in August. It must've worked but I wonder how well. We shall see. I'm not going to ride this thing very hard, too old and am mainly into bikes for casual rides and restoration activities these days.

I was thinking of rebuilding the original Keihin but ditched that idea after reading up on it. Plus there was a little bourbon related accident in the garage and I lost the main jet somewhere, and said F it - I went ahead and ordered a Mikuni HSR42 as that was highly recommended by several online. I will have the two adapters, one to mount to the turbo and the other part of the carb kit for mounting the air cleaner assembly. I'll get the round 5.5" chrome round filter unit, it's common, inexpensive, fits with my side cover, and is what came with the kit originally. I will use my push/pull (pull pull?) throttle on the Mikuni if all goes to plan.

I am going to roll the dice on the turbo after a chat with the seller who said it had been rebuilt, and with a guy at Roto-master who said if it turns and doesn't leak oil, it should be good. Rebuild would be an opportunity to have it really cleaned and polished but it's not bad after some careful polishing on my own.

In the end if it has any problems like bad oil seals or turbo malfunction I'll just fix them then.

Oil cooler:

[oldGSfan]

Thanks, getting to the turbo/carb/wiring etc, so the real fun begins.

Man that's starting to really take shape now, love your work!

[pete]

Man that's starting to really take shape now, love your work!

[oldGSfan]

I got the little rubber grommets for the headlight bracket so I put the front end on, but I forgot one of the little air fitting shrouds that I painted up, d'oh! Oh well quick to fix that. I have to support with the hoist, because the side and center stand are still being powder coated. The original wheels are on for rolling around, while the EPMs are being stripped and bead blasted. Found a wheel shop that does it for $30 each, what a deal. I should have stands and wheels next week. I'm fabricating the forward side cover mount for one side, it was cut off to allow the big S&S air cleaner that I won't use, and with the smaller air filter I will be able to put the side cover on.

I also got my Earl's brake lines so I will get those together this weekend. That will leave just a few things to do and buy.

I wonder if anyone would want to trade my cut down seat for a stock one. I don't mind the look but I'm 6'3" and it is too low.

[oldGSfan]

I fitted the exhaust, mounting flanges were bent so I straightened as best I could, pretty close. I have new gaskets. I always find installing 4 of them to be a juggling act. I think I used some masking tape in the past to hold in place then pulled out when loosely mounted. I need gaskets for the 3 bolt round flanges, will measure and see if they are a standard size. Hope so.

[oldGSfan]

Thanks, yeah that is actually the last thing I'm waiting on, otherwise I'd have the front end together. They are on order from Partzilla, can't wait to have it on 2 wheels.

Love this bike makes me want get my 82 prettier. Side note your headlight brackets are missing the rubber between the fork tube an bracket. My 82 has them

[suzukigs1100ez]

Love this bike makes me want get my 82 prettier. Side note your headlight brackets are missing the rubber between the fork tube an bracket. My 82 has them

[oldGSfan]

Thanks Rob, I'll start with stock 15/42 (from memory) setup because it matches the chain I have, then go smaller in back, I think. I will need to be careful, set to -10 lbs boost to start. I think Ill end up somewhere in the middle, I have a few sizes to choose from. My Multistrada has 150HP but doesn't feel all that much stronger than my old GS, from memory anyway. Gets happy up front more though.

Best movie I've seen all year.

You won't be going with gearing as tall as 184 mph, will you?

[Rob S.]

Best movie I've seen all year.

You won't be going with gearing as tall as 184 mph, will you?

[oldGSfan]

I uploaded a video walk (squat?) through.

[oldGSfan]

Wow! That looks great.
Interesting custom oil pickups as well.

Thanks Steve. I spent a long time on the stainless and chrome header/muffler today. I used barkeeper's friend and red (brown?) Scotchbrite, regardless if it's that or baking soda or whatever else, it is mainly elbow grease. It took a good 3 hours, once I did part of the small pipe I was energized to finish up. I was considering Jet Hot or Cera Kote which I still may do someday, but wanted to get it decent and see how it runs before sinking a bunch of $ into these parts. There are some blemishes but overall I'm very happy that they could be brought to this condition, considering the level of tarnish.

I used some diluted muriatic acid on the rust at the welds and flanges, which worked great. I still have rust in the crook of the pipe I may try to get at, and then perhaps some brush-on silver high heat paint. Gotta check those welds for any leaks too, and if so, get them sealed up.