82 GS1100E Mr Turbo Rebuild

[oldGSfan]

OK 2 more...by the way he said it's not a 'real' streamliner class, that was different, but since it had a fairing it fell into this class.

Bombs away, please.

Those brass plaques are extremely cool. Bike's just two years old, runs 174, then a month later turns a 175. That tiny fairing hardly seems 'streamlined' these days.

[Rob S.]

I don't want to photobomb this site too much so just a couple for now.

Bombs away, please.

Those brass plaques are extremely cool. Bike's just two years old, runs 174, then a month later turns a 175. That tiny fairing hardly seems 'streamlined' these days.

[oldGSfan]

Thanks Chris, I appreciate the interest. The tool is not an allen, at first I thought it might be, as I watched a YouTube video, but these are different, just round holes. I'll figure it out, may get done, Race Tech makes a universal tool and a friend's shop has one.

Everything will be as good as it can get, I am very meticulous and have restored many bikes. This is by far the one I'm most thrilled about. Today I went to the seller's house (with mask and gloves out of courtesy). He gave me a new service manual, 3 new sprockets to fit the EPM wheels, in various sizes, plus new in boxes DID #630 O-ring chain and a Diamond that looks like it's non O-ring. Boxes of parts including heavy duty APE cylinder studs, new barrel sleeves, plus some missing stuff - center stand, another headlight (now have 3 with 2 buckets and trim), and best of all, a ton of Bonneville posters, programs, time slips. Got two brass plaques (from El Mirage) as shown. Also his original check for the new bike purchase, tool kit, spare wiring harness, and so on. I took photos of his scrap book and promised him to make a real presentation of it for shows, which I hope to enter, and bring him to, after life returns to normal. I don't want to photobomb this site too much so just a couple for now. He's in the red T shirt, letting a friend take a ride.

Hi, it looks like your project is coming along fine. It's cool that you are overhauling everything, brakes suspension ect. that is the best way to rebuild a almost 40 year old bike. I don't recall needing any special tools to overhaul the forks with maybe the exception of a 17 or 19 mm ( can't remember the size ) allen socket with a long extension. I could not find that special tool part number in the factory service manual but mine is a canadian bike. Forks look identical to my bike , are you going to take the anti-dive stuff off ? I am really enjoying this thread.

[chris]

Hi, it looks like your project is coming along fine. It's cool that you are overhauling everything, brakes suspension ect. that is the best way to rebuild a almost 40 year old bike. I don't recall needing any special tools to overhaul the forks with maybe the exception of a 17 or 19 mm ( can't remember the size ) allen socket with a long extension. I could not find that special tool part number in the factory service manual but mine is a canadian bike. Forks look identical to my bike , are you going to take the anti-dive stuff off ? I am really enjoying this thread.

[oldGSfan]

The seller called me and said he found 3 more boxes of parts in his garage, evidently he had filled said garage to the brim. The only pieces missing are the headlight brackets and speedometer drive housing, but I already got a nice drive off eBay for 15 - if so I may resell that, it came with cable and guide, in great shape too. I expect he has them as he seemed to keep everything.

Had a nice chat with him, and will take pics of his scrapbook from Bonneville when I fetch the stuff Saturday. He claims that at >180 mph it was the fastest street registered bike from '83 to '91. Nowadays you can buy a new bike that goes over 200, crazy.

I cut the rock hard Dunlop slicks off. That was hard work, used a hand saw and box cutter to slice the tire up, and a Dremel on the wire bead. Looking at new tires, the ones I need are odd sizes these days, rear EPM wheel is 18x3.5" and front is 18x2.5. 130/80-18 rear and 100/90-18 front should work. The Conti Go! may fit the bill as those sizes are available - not many choices.

I have various new spare sprockets for the EPM wheels (unobtanium I bet) but have to stick with a #630 chain. He says he has some nice ones in the boxes, but will see. The bike has many specially made parts, he had a machinist friend - extended left side footpeg and shifter for example, as the exhaust runs up like a scrambler, and is wide.

I talked to a tech at Rotomaster about the turbo, he said if it isn't leaking oil (and it isn't) it should be OK. Rebuild kits which consist of just a few gaskets/bearings/seals are $300 and may be unavailable so we'll see, that's a few months off anyway. I'm making great progress. Forks and brakes are stripped down, parts on the way but slow due to you know what. Brake cylinders and pistons are all fine. Forks are presenting a challenge, as I need that special tool, blind hole bearing puller, #09940-34561. Or I can take to a local MC shop my friend own

[limeex2]

No screen with that, though.

I found on the same site, a kit that had brackets, fairing and screen.

[Spyder]

I had to use my stock springs on my Progressive shocks. I CAREFULLY, cut the shaft of the stock shocks with a 6" cutoff wheel. It was a little tedious, but it worked.

[oldGSfan]

Yeah they're the stock ones, I know they are pretty mediocre. I ran Progressive 12 series on my old 82 GPz1100 and liked them. Had some nice vintage Fox piggyback ones on my '82 Katana too. I just want to have something on there until I figure out what nice ones I'll get.

What brand shocks are you working on
Stock?
Stock shocks are mediocre compared with modern shocks.

[Big T]

I have a question about shocks if anyone can help...

I have two sets of shocks, and think I can make one good set out of the pair. The ones on the bike set came apart easily because the springs were modified to be shorter, and had no tension. The dampers seem to be fine, chrome good etc. The bolt on the piston shaft reached its limit where the threads end, and the top came right off.

I used my vice and some ratchet straps to compress the springs on the pair with the good springs, but the bolt never reached the limit and now it's locked in place, if I lean on it I'll round the nut off.

Any ideas? It's soaking with liquid wrench but I think it's a lost cause. Sawzall the piston shaft?

What brand shocks are you working on
Stock?
Stock shocks are mediocre compared with modern shocks.

[dorkburger]

Not a bike but this is what I work on when not messing with MCs, Mountain bikes, and the house.

'54 Willys Wagon (350 SBC, TH400, NP208, Scout II Dana 44s, A/C, Power disc brakes, steering) and '69 Airstream Caravel 18'.

Excellent! You travel in style.

[oldGSfan]

I have a question about shocks if anyone can help...

I have two sets of shocks, and think I can make one good set out of the pair. The ones on the bike set came apart easily because the springs were modified to be shorter, and had no tension. The dampers seem to be fine, chrome good etc. The bolt on the piston shaft reached its limit where the threads end, and the top came right off.

I used my vice and some ratchet straps to compress the springs on the pair with the good springs, but the bolt never reached the limit and now it's locked in place, if I lean on it I'll round the nut off.

Any ideas? It's soaking with liquid wrench but I think it's a lost cause. Sawzall the piston shaft?

[oldGSfan]

Not a bike but this is what I work on when not messing with MCs, Mountain bikes, and the house.

'54 Willys Wagon (350 SBC, TH400, NP208, Scout II Dana 44s, A/C, Power disc brakes, steering) and '69 Airstream Caravel 18'.

[oldGSfan]

Today I removed the engine, the old furniture dolly, skateboard and chain hoist trick. I had it all ready to go and I couldn't get the frame off the engine due to a tab that the PO welded on for the steering damper. I had to put the engine mount bolts back in flip it around to the other side, but no big deal. Still pinching myself as I take it apart, there is zero wrong, it's all there with spares galore.

[pete]

Well done! Patience is a virtue, and in these situations it 100% takes things from a nightmare to doable. No doubt there are other things on people's minds right now so giving them some slack and being calm and patient is the right way to go.

[Spyder]

Sound like a brutal day at the BMV to be sure. But you got it. Can't wait to see some video of this beast running and rolling.