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Another Rebuild from Blighty

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  • Another Rebuild from Blighty

    OK Boys & Girls after getting my GSX1100FL around 2 years ago it has sat in the garage whilst I tackled one job then another until I decided to go for broke, I've not finished it yet but I've got plenty to show you of what's been happening.
    After the 130 odd mile ride home after buying the bike I realise what a pile of crap the bike had been made into and bodged all over so as the saying goes one thing leads to another so I will start with the leaking tank.



    One of these kits is a good place to start



    Tank need to be cleaned, rust removed and dried properly before sealing which is the easy bit. I started by defuelling and getting the sender and tap out.



    That is rust on the end of a telescopic magnet, plenty more where that came from!



    All masked up and ready to go with the marine wash, stabilizer and rinse



    Find a nice place to use a hose and choose your fave bath towel



    Once that's done and thoroughly rinsed move inside and break out the wife's hair dryer, the tank does get quite hot so a good opportunity to change the tank pad as it just falls off, this took ages but it has to be perfectly dry.



    Both ends get blasted



    Now for the good bit, pour in the sealer after a good shake & stir using an old bog roll inner



    After working it in the nooks and crannies by twisting and turning I was satisfied it had covered the whole inside so let it drain over night and loads found its way out onto the paper by morning.



    Saved a bit for the filler neck.



    Next up, why was the chain catching the tyre, well apart from having a GSXR1100M 5.5 rim and a 180 tyre it hadn't been done very well







    Last edited by Locomotion; 04-04-2014, 07:22 AM. Reason: Automerged Doublepost
    If it aint broke polish it

    1979 GS7/11 - 1990 GSX1100F

    My Rebuild
    http://katriders.com/vb/showthread.php?t=133928

  • #2
    Carpe Jugulum...
    1994 GSX1100F

    Please check out my re-build thread: http://katriders.com/vb/showthread.php?t=128660

    Comment


    • #3
      A few calculations





      Using precision drawings


      I concluded I would go with a 170 tyre and a not so wide Gixxer sprocket carrier

      Not the best pic but better wheels and exhaust together with new C & S



      Yes saw yours Engelskmannen very good and read with interest, no doubt will be doing some of the stuff you covered.

      Will be back soon with frame restore, engine rebuild, wiring, blah blah blah £££`s
      Last edited by Locomotion; 04-04-2014, 07:42 AM. Reason: Automerged Doublepost
      If it aint broke polish it

      1979 GS7/11 - 1990 GSX1100F

      My Rebuild
      http://katriders.com/vb/showthread.php?t=133928

      Comment


      • #4
        Good work! Need to restore my girlfriend GS550 Tank this summer, this will be a good reference.
        - Josh

        2003 Suzuki Katana 600, Two Brothers Carbon Fiber exhaust, plasti dipped black and green (almost). I live and ride in Upstate NY.

        Comment


        • #5
          Awesome, I'm wrapping up another project before diving into my own 1100 rebuild. Tank and chain/sprockets on mine need some tlc also. Thanks for lots of pics!
          1998 Katana 750
          1992 Katana 1100
          2006 Ninja 250

          2006 Katana 600 RIP - 130k miles

          Comment


          • #6
            Originally posted by Locomotion View Post
            A few calculations





            Using precision drawings


            I concluded I would go with a 170 tyre and a not so wide Gixxer sprocket carrier

            Not the best pic but better wheels and exhaust together with new C & S



            Yes saw yours Engelskmannen very good and read with interest, no doubt will be doing some of the stuff you covered.

            Will be back soon with frame restore, engine rebuild, wiring, blah blah blah £££`s



            Your problem with the rear carrier is that it's the original 1100 kat carrier, put on a gsxr wheel. The chain clearance would be fine if you used the correct 1100 GSXR carrier with the wheel. That would give you proper clearance for the sprocket and chain to the wheel.


            Krey
            93 750 Kat



            Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

            "I've done this a thousand times before. What could possibly go wron.... Ooops!"

            Comment


            • #7
              Which is what I did Krey, clearance is ok now
              If it aint broke polish it

              1979 GS7/11 - 1990 GSX1100F

              My Rebuild
              http://katriders.com/vb/showthread.php?t=133928

              Comment


              • #8
                Ok now to the engine strip as the engine had a few oil leaks I had to pull it apart, the bad design of this bike is having to remove the engine to remove the head and then the rear doesn't clear the frame, anyways here goes



                Off with his head, that's the previous owner not the bike, I don't approve with the use of Red Hermatite on these areas as it always seem to find its way into the engine plus its a pain in the arse to remove.



                On the bench ready for total strip clean and repair



                The outer stud holes were damaged on removal as the copper washers were stuck to the threads of the stud preventing me removing the head, that will be machined.



                Exhaust threads made of chocolate, 3 were replaced with timeserts which are far superior to helicoil which you can see one was hanging out



                Stripped and cleaned ready for inspection



                Here are the oil drains which had been bodged will sealer to try and stop the leak, previous bodger reckons he was a fully trained Suzuki mechanic, yeah right. see the copper washers which I had to unscrew from the studs, I think they were in the wrong place to start with



                Pistons not damaged, will measure up later



                Another reason not to use Red Hermatite, not pretty there a valve keeper and a locating pin for the cam cover tut tut

                Last edited by Locomotion; 04-06-2014, 09:04 AM. Reason: Automerged Doublepost
                If it aint broke polish it

                1979 GS7/11 - 1990 GSX1100F

                My Rebuild
                http://katriders.com/vb/showthread.php?t=133928

                Comment


                • #9
                  Pure bike porn... more please

                  Colin.
                  Carpe Jugulum...
                  1994 GSX1100F

                  Please check out my re-build thread: http://katriders.com/vb/showthread.php?t=128660

                  Comment


                  • #10
                    Barrel faces ready for a clean



                    Studs most of which are bent



                    Not the best design of engine, that cam chain guide is a right barsteward when removing barrels and more so when replacing



                    I removed the top crankcase from the bottom cranckcase as it was easier but should have been designed this way as the crank end float shells sit in the top half together with the gearbox



                    Another reason the bottom has to go onto the top on rebuild, these are the cam guide bushes



                    These small oil jets lube the gearbox bearings, removed prior to cleaning



                    Case faces will be cleaned up using oil stone



                    Full of crap, 45k miles worth





                    Ready for cleaning and inspection



                    Main bearing shells removed ready for degreasing and power washer



                    Now where do those bolts go again



                    Next time head strip, valves etc
                    Last edited by Locomotion; 04-06-2014, 09:44 AM. Reason: Automerged Doublepost
                    If it aint broke polish it

                    1979 GS7/11 - 1990 GSX1100F

                    My Rebuild
                    http://katriders.com/vb/showthread.php?t=133928

                    Comment


                    • #11
                      Originally posted by Engelskmannen View Post
                      Pure bike porn... more please

                      Colin.
                      +1

                      Wow you are going balls out on this rebuild. Wish I had that kind of mechanical knowledge
                      1998 Katana 750
                      1992 Katana 1100
                      2006 Ninja 250

                      2006 Katana 600 RIP - 130k miles

                      Comment


                      • #12
                        Incredible rebuild going on here man. Top work

                        Can't believe someone can walk away from a tire job with the chain catching the tire.
                        - Purplehaze
                        All-Black 1993 Suzuki Katana 600 (Click for pictorial fun!)

                        Comment


                        • #13
                          Plenty more to come guys
                          If it aint broke polish it

                          1979 GS7/11 - 1990 GSX1100F

                          My Rebuild
                          http://katriders.com/vb/showthread.php?t=133928

                          Comment


                          • #14
                            Carpe Jugulum...
                            1994 GSX1100F

                            Please check out my re-build thread: http://katriders.com/vb/showthread.php?t=128660

                            Comment


                            • #15
                              Head stripped out ready for light skim, repair to inside faces where the outer stud holes come through and 3 exhaust port threads.



                              Break out my 20 year old Chemico grinding paste



                              Spot the difference



                              Fitting the valves, I always use a smidge of grease to hold the collets in place



                              Nice new stem seals which are sold at extortion in the UK, thanks to good old fleabay USA



                              Note stud hole at bottom of pic which has been machined flat. Due to limited access the copper washer was a pig to remove and I damaged the face.



                              Excuse the ropey pic but you get the idea





                              Nice new stainless studs will preserve the chocolate threads



                              Next time cylinders
                              If it aint broke polish it

                              1979 GS7/11 - 1990 GSX1100F

                              My Rebuild
                              http://katriders.com/vb/showthread.php?t=133928

                              Comment

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