tag:blogger.com,1999:blog-12112830336328684592024-03-22T00:45:29.704+00:00Suzuki GS1100 G Restoration ProjectWelcome to my 1983 GS1100 G Restoration Project. This bike has been in my family since new. It was bought by my Dad new in 1985 in Ontario, Canada. He toured the US with it with my Mum on the back (both have since passed away). I imported it into the UK around 1996 and rode it around London for a couple of years. Then it sat in the garden for 10 yrs (oh the horror!). Now: RESTORATION. Please use contact form page for comments. Click on photos to enlarge. Project started 18th August, 2012.Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comBlogger131125tag:blogger.com,1999:blog-1211283033632868459.post-56861239727823224202021-03-07T11:26:00.003+00:002021-03-07T12:44:13.100+00:00Vapour Blasting Horror<p>Having let the project slip for a few years, I picked up on the engine to start the process of preparing it for paint. A lot of people had warned me that I needed to check all the oil passageways for the ingress of vapour blasting media.</p><p>This is a very fine sand like substance and because of the high pressures used in vapour blasting, it gets into all the small oil passageways in the head, and other parts of the engine that were blasted.</p><p>I bought one of those cheap iPhone endoscopes and I was horrified at what I saw.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://lh3.googleusercontent.com/-F-6PkPhGu5A/YES26Iu2-SI/AAAAAAAAVXo/Ik86D_-iq6kzgSyCcoUYOpx3Z-XNf4BtACLcBGAsYHQ/IMG_6430.JPG" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2048" data-original-width="1536" height="240" src="https://lh3.googleusercontent.com/-F-6PkPhGu5A/YES26Iu2-SI/AAAAAAAAVXo/Ik86D_-iq6kzgSyCcoUYOpx3Z-XNf4BtACLcBGAsYHQ/IMG_6430.JPG" width="180" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">And what came out</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://lh3.googleusercontent.com/-fiAYvCwJTDo/YES3AxbMVKI/AAAAAAAAVXs/MBK-NJqMh8I5jBRSxZyrHmKZCFddxHnbACLcBGAsYHQ/IMG_6431.JPG" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="1652" data-original-width="1190" height="240" src="https://lh3.googleusercontent.com/-fiAYvCwJTDo/YES3AxbMVKI/AAAAAAAAVXs/MBK-NJqMh8I5jBRSxZyrHmKZCFddxHnbACLcBGAsYHQ/IMG_6431.JPG" width="173" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/eJp76tKnwHA" width="320" youtube-src-id="eJp76tKnwHA"></iframe></div><br /><div class="separator" style="clear: both; text-align: center;">There are a whole load of passageways that need to be cleaned. Some of them are dead ends where this media will be hard to get out.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;">There was only one way to get the job done completely. The plugs in the cylinder head that were created when the passageways were drilled into the head during manufacture, will need to be pulled out. There are 10 of these plugs on the cylinder head. They are soft aluminium. I drilled them, tapped them and made a puller from a socket and bolt.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://lh3.googleusercontent.com/-Y5_BkFFPkhw/YETC2no1sKI/AAAAAAAAVX4/qOp3EfO3zTwt2VXxPO_KaR1gvsZy7cDlgCLcBGAsYHQ/IMG_6703.JPG" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="1536" data-original-width="2048" height="240" src="https://lh3.googleusercontent.com/-Y5_BkFFPkhw/YETC2no1sKI/AAAAAAAAVX4/qOp3EfO3zTwt2VXxPO_KaR1gvsZy7cDlgCLcBGAsYHQ/IMG_6703.JPG" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://lh3.googleusercontent.com/-JIFljarVTLM/YETDAsjxueI/AAAAAAAAVX8/LkloXxnZMAMg4AQgZOsoCMUK8jjZAVxtwCLcBGAsYHQ/IMG_6709.JPG" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2048" data-original-width="1536" height="240" src="https://lh3.googleusercontent.com/-JIFljarVTLM/YETDAsjxueI/AAAAAAAAVX8/LkloXxnZMAMg4AQgZOsoCMUK8jjZAVxtwCLcBGAsYHQ/IMG_6709.JPG" width="180" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://lh3.googleusercontent.com/-H9K75KMz8r8/YETDDdYisHI/AAAAAAAAVYA/6I1CltTIJR08V0uGDKLGIwtaW8DI-pYwgCLcBGAsYHQ/IMG_6708.JPG" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2048" data-original-width="1536" height="240" src="https://lh3.googleusercontent.com/-H9K75KMz8r8/YETDDdYisHI/AAAAAAAAVYA/6I1CltTIJR08V0uGDKLGIwtaW8DI-pYwgCLcBGAsYHQ/IMG_6708.JPG" width="180" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://lh3.googleusercontent.com/-oSsYo1dndR8/YETDEvmNyuI/AAAAAAAAVYE/gS5MzCHokmM1vA7HFbxhclMyHz-t5DT7gCLcBGAsYHQ/IMG_6710.JPG" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2048" data-original-width="1536" height="240" src="https://lh3.googleusercontent.com/-oSsYo1dndR8/YETDEvmNyuI/AAAAAAAAVYE/gS5MzCHokmM1vA7HFbxhclMyHz-t5DT7gCLcBGAsYHQ/IMG_6710.JPG" width="180" /></a></div><div class="separator" style="clear: both; text-align: center;"><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://lh3.googleusercontent.com/-baR6Z-Vy-cA/YETDIu7zy7I/AAAAAAAAVYI/AYsU112iuVcgLtoB5jz8dS6ejMSqPtc7gCLcBGAsYHQ/IMG_6764.JPG" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2048" data-original-width="1536" height="240" src="https://lh3.googleusercontent.com/-baR6Z-Vy-cA/YETDIu7zy7I/AAAAAAAAVYI/AYsU112iuVcgLtoB5jz8dS6ejMSqPtc7gCLcBGAsYHQ/IMG_6764.JPG" width="180" /></a></div></div><div class="separator" style="clear: both; text-align: center;"><br /></div>And just look at the horrible build up of media that been trapped in these places.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://lh3.googleusercontent.com/-gSURF8MSnQs/YETDYD0GJKI/AAAAAAAAVYc/EeOPOsMpweMSOYnWaXUyreY13Rh8WN46QCLcBGAsYHQ/IMG_6765.JPG" style="margin-left: 1em; margin-right: 1em;"><img alt="" data-original-height="2048" data-original-width="1536" height="240" src="https://lh3.googleusercontent.com/-gSURF8MSnQs/YETDYD0GJKI/AAAAAAAAVYc/EeOPOsMpweMSOYnWaXUyreY13Rh8WN46QCLcBGAsYHQ/IMG_6765.JPG" width="180" /></a></div><br />ANY amount of this stuff in your oil and goodness only knows how any of the bearings would have survived.</div><br /><br /></div><br /><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><br /><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><br /><br /></div><br /><br /><p></p>Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-28269619889465687762018-12-29T18:01:00.000+00:002018-12-29T21:27:33.166+00:00Clutch Selector Bearing Stuffed<div style="text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">I didn't notice this for a while but it looks like the guys who vapour blasted my cases, saw that there was a bearing still in there and attempted to get it out.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">Well they botched that pretty bad. Gouging out the inner part of the bearing and leaving the outer shell in place after marking up the cases pretty badly.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">With the help of some technically adept motorbike mates, we got the shell out and smoothed off the damage.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">This is how it looked when it was sent for blasting (OK I should have got it out myself):</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="http://4.bp.blogspot.com/-HhACWknA6fE/XCewYzeDYuI/AAAAAAAASLg/YOKOhwrGeIwY-Bz78qEEFm4R-fN5fx9DwCK4BGAYYCw/s1600/IMG_3299.JPG" imageanchor="1"><img border="0" height="240" src="https://4.bp.blogspot.com/-HhACWknA6fE/XCewYzeDYuI/AAAAAAAASLg/YOKOhwrGeIwY-Bz78qEEFm4R-fN5fx9DwCK4BGAYYCw/s320/IMG_3299.JPG" width="320" /></a></span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">and this is what came back from the blasters:<br /><br /><a href="http://2.bp.blogspot.com/-M0IeKVT1gNM/XCew3NCQ9yI/AAAAAAAASLs/zU1giwDCttM3mDxbhcrjBxquOksSFTlZgCK4BGAYYCw/s1600/IMG_4596.JPG" imageanchor="1"><img border="0" height="320" src="https://2.bp.blogspot.com/-M0IeKVT1gNM/XCew3NCQ9yI/AAAAAAAASLs/zU1giwDCttM3mDxbhcrjBxquOksSFTlZgCK4BGAYYCw/s320/IMG_4596.JPG" width="240" /></a></span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">so we took the Dremel to it:</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="http://4.bp.blogspot.com/-8J7WX0gSwHE/XCe1t0wXB2I/AAAAAAAASL4/_Z2h-US1rosO6ViQUmsfcYoumXwxnY75ACK4BGAYYCw/s1600/IMG_8042.JPG" imageanchor="1"><img border="0" height="320" src="https://4.bp.blogspot.com/-8J7WX0gSwHE/XCe1t0wXB2I/AAAAAAAASL4/_Z2h-US1rosO6ViQUmsfcYoumXwxnY75ACK4BGAYYCw/s320/IMG_8042.JPG" width="240" /></a></span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">and out it came:</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><a href="http://2.bp.blogspot.com/-NfToJaRwKEc/XCe12RMraiI/AAAAAAAASMA/H0EgeQyez0Yqgjri6uimnxHLYzNhoEtbACK4BGAYYCw/s1600/IMG_8045.JPG" imageanchor="1"><img border="0" height="240" src="https://2.bp.blogspot.com/-NfToJaRwKEc/XCe12RMraiI/AAAAAAAASMA/H0EgeQyez0Yqgjri6uimnxHLYzNhoEtbACK4BGAYYCw/s320/IMG_8045.JPG" width="320" /></a></span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">New bearing had a lot more rollers on it and will go back in after the painting has been done.</span></div>
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<a href="http://4.bp.blogspot.com/-oFv7bG4Ia68/XCe2TXx5_pI/AAAAAAAASMQ/SSAEsgpDsRceU8qvt1ZXcj-OUOwqqvHoACK4BGAYYCw/s1600/IMG_8125.JPG" imageanchor="1"><img border="0" height="320" src="https://4.bp.blogspot.com/-oFv7bG4Ia68/XCe2TXx5_pI/AAAAAAAASMQ/SSAEsgpDsRceU8qvt1ZXcj-OUOwqqvHoACK4BGAYYCw/s320/IMG_8125.JPG" width="240" /></a><br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-56941691306555179812017-04-17T10:29:00.003+01:002017-04-17T10:30:42.128+01:00Vapour Blasted Engine Comes Home<br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;">Got the cases back now. They did an aggressive blasting to try and eliminate all the corrosion. Mostly this has worked well but still a few places where I'm going to have to wet and dry.</span></div>
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In any case (get it?) it's a good finish for painting. The cam cover I have painted as my test piece using VHT paints; Engine Enamel Primer, Barrel Paint and Satin Clear Clear. Comes up good.</div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">And a reminder of what I started with:</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><br /></span>Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-38591374054206126872016-11-05T14:35:00.001+00:002016-11-05T14:35:30.097+00:00Head Comes Apart<div style="text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">All the valves need taking out and clearances checked.</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-32672364868789155792016-11-05T14:28:00.001+00:002016-11-05T14:30:41.955+00:00Gear Box Components Out<div style="text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">For vapour blasting all the internals need to come out.</span></div>
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<span style="font-family: Arial, Helvetica, sans-serif;">Including this roller bearing that supports the gear selector drum.</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-64434450560837650322016-11-05T14:19:00.001+00:002016-11-05T14:19:06.794+00:00And How Are Things Inside?<div class="separator" style="clear: both; text-align: center;">
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<span style="font-family: Arial, Helvetica, sans-serif;">Quick look at the pistons: they have very few marks on their side but are quite sooty. I guess they were quite carbonned up, even though the mileage wasn't high. I sprayed WD40 into the barrels several times over the years to stop any corrosion and that's a good way to loosen up the deposits. They are very soft now.</span></div>
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<span style="font-family: Arial, Helvetica, sans-serif;">To get the crank out it was necessary to take off pistons 1 and 4.</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-29410992765082999052016-11-05T14:08:00.002+00:002016-11-05T14:08:56.895+00:00Cases Ahoy!<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">Now to get the cases apart and not to forget all the bolts top and bottom and the retaining plate clutch side. (Click on images to enlarge)</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-49663511818322230212016-10-09T18:39:00.004+01:002016-10-09T19:54:27.817+01:00Sump Comes Off<div style="text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">Lets see what's happening in the sump - always tells you what's been going on in the engine:</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;"> There was a little bit of gunk in the bottom - nothing to worry about considering this motor has been idle for at least 15 years.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">And with the filter, I took the mesh off and there was nothing in it at all.</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-60007818154030110492016-10-09T18:39:00.003+01:002016-10-31T13:32:36.920+00:00Tacho Drive<div style="text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">Looks like new rubber seals in the tacho drive are needed. One seal and one O ring.</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-6550276161163867302016-10-09T18:39:00.001+01:002016-10-09T18:39:37.166+01:00Barrel Off<div style="text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">Head came off easily but the barrel didn't want to move. Lots of gentle knock with bits of wood and even a bit of levering.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">Ready for taking to the vapour blaster.</span></div>
Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-5514296996657956462016-10-09T18:20:00.001+01:002016-10-09T18:27:31.755+01:00Head Off (1,523 Days into the project - how bad is that?)<div style="text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">Got the head off. I was very surprised at the carbon build up on the pistons and combustion chamber for such a low mileage motor.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;"> Honing still visible:</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">But the cam chain guides show very little wear:</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-51619380283505959132016-10-08T20:28:00.003+01:002016-10-08T20:44:15.113+01:00Engine Comes Apart<div style="text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;">It's been some time (well nearly 2 years) since I last posted for this build. Several other bike projects came along ( have you ever heard that before) and distracted me.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">I was in debate as to whether to strip the engine or to try and clean it up as a lump. It was very corroded in parts and I couldn't find a vapour blaster who would take on the job of doing the engine as one lump.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">The corrosion is bad:</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">There was no way this was going to clean up without some form of blasting. So today I decided to start stripping the engine down so it could all be vapour blasted prior to repainting.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">So here we go. Cams out first:</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">The journals are looking good. Well they've only done about 15,000 miles.</span></div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;">And the camshaft lobes are like new.</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comCanterbury, UK51.280233 1.078908899999987651.2007715 0.91754739999998769 51.3596945 1.2402703999999876tag:blogger.com,1999:blog-1211283033632868459.post-33960388150972917942014-12-14T20:35:00.003+00:002014-12-14T20:35:38.806+00:00Steering Stem Mock Up (Day 848)<div style="text-align: center;">
<span style="font-family: Arial, Helvetica, sans-serif;">After months now (nearly 10) I have retrieved the frame from the loft where it had been resting all summer. During the summer I was inadvertently distracted by the purchase of a GS1150ES (we know them as a GSX1100) and getting my Road Runner bike ready for a tour of Europe.</span></div>
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<span style="font-family: Arial, Helvetica, sans-serif;">See: my <a href="http://suzukigs1150es.blogspot.co.uk/" target="_blank">GS1150ES Restoration Blog</a> ant my <a href="http://suzukigs1100g1982.blogspot.co.uk/" target="_blank">GS1100G Road Runner Project Blog</a> </span></div>
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<span style="font-family: Arial, Helvetica, sans-serif;">So Dad's bike has very much been neglected. Now it is in my home office and it can no longer be ignored. I am going to set the front up (no wheels) and attach the swing arm and as many items as I can over the winter. I hope to have a rolling chassis by the summer when I will concentrate on getting the engine ready to re-install.</span></div>
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<tr><td style="text-align: center;"><a href="http://4.bp.blogspot.com/-Tz9oqbbsdF4/VI3z4dC40LI/AAAAAAAAKPU/IiZGNJ98Ih8/s1600/P1120798.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="http://4.bp.blogspot.com/-Tz9oqbbsdF4/VI3z4dC40LI/AAAAAAAAKPU/IiZGNJ98Ih8/s1600/P1120798.jpg" height="213" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span style="font-family: Arial, Helvetica, sans-serif; font-size: small;">My anticpated completion date is now looking like the summer of 2016.</span></td></tr>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-44711589732382586812014-03-03T20:42:00.001+00:002014-03-03T22:12:57.724+00:00Installing Bearing on Lower Steering Yoke Stem (Day 562)<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">I found a neat little tool to help seat this bearing on the stem. Do the usual tricks of putting the stem in the freezer, heating up the bearing in the oven and oiling the stem. Then use the fork stanchion turned upside down as the bearing driver. It's dimensions are just right to fit inside the bearing to put pressure on the correct part. I used to rubber mallet to drive it home quite easily. Be careful not to damage the delicate threads at that end of the stanchion as you put it over the stem.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> It's a perfect fit.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Home and dry.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">I nearly forgot the washer when I started.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> But it is there.</span></div>
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<br />Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-66817550558064600262014-01-12T17:33:00.000+00:002014-03-25T19:30:43.699+00:00De-Painting Inside of Yokes<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">The powder coating had to be taken off the inside of the fork yokes or Ts.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Fork stanchions slide in quite nicely now.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Be careful not to hit any outer surfaces with that abrasive.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">And BEFORE you test putting in the stanchions, clean out all the grit so the stanchions do not get scratched.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Then I need to work out if the flat section, where the bearing will rest, needs to be cleaned up too. My surface here is quite lumpy. I don't think this is paint build up but it could be and there is also a washer that should cover it up. I don't want it to settle at a later date forcing me to do another head adjustment.</span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-27765045432396248182014-01-12T16:01:00.002+00:002014-01-19T16:07:38.603+00:00Steering Head Assembly Issues<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">Just been pointed out that due to the powder coating reaching the insides of the fork yoke clamps, it is unlikely that I will be able to put the stanchions back in with removing the paint. You can see here how beautifully the insides have been painted. Oh dear!</span></div>
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<a href="http://4.bp.blogspot.com/-KKpPto-0_tw/UtK65yJswOI/AAAAAAAAHhI/tF6qW1TqabY/s1600/P1090612.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://4.bp.blogspot.com/-KKpPto-0_tw/UtK65yJswOI/AAAAAAAAHhI/tF6qW1TqabY/s1600/P1090612.jpg" height="213" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> And indeed the fork stanchion will not go in.</span></div>
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<a href="http://3.bp.blogspot.com/-0P6cET6MrVc/UtK6431oDnI/AAAAAAAAHgo/6zJzQqluEHE/s1600/P1090606.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://3.bp.blogspot.com/-0P6cET6MrVc/UtK6431oDnI/AAAAAAAAHgo/6zJzQqluEHE/s1600/P1090606.jpg" height="213" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> And this is why. It is trying to scrape the paint off.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Is this the way to do it?</span></div>
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<br />Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-46685045889897623212014-01-11T20:31:00.002+00:002014-01-12T09:55:51.311+00:00Preparing Steering Head For Reassembly (Day 511)<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">After some time dealing with my other bike (<a href="http://suzukigs1100g1982.blogspot.co.uk/" target="_blank">My GS1100G Road Runner Blog</a>) and enjoying riding it over the last part of the summer of 2013, I am back on the original project and I am starting on the frame / forks reassembly.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">All of my parts and frame have been beautifully powder coated at <a href="http://www.performance-powdercoating.co.uk/" target="_blank">Performance Powder Coating</a> in East Kent.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"><span style="font-family: Arial,Helvetica,sans-serif;">Now I am preparing to reassemble the steering head.All the powder coated parts look great and we are ready to go.</span> </span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">The stem was
wrapped in masking tape that was baked at high temperature. This meant the tape was very hard to remove and when it did come off it left a sticky
residue.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Removing all the sticky tape glue with a "sticky stuff" remover.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Then I needed to dress the damage I had done when I was busting off the old race with the Dremel.</span></div>
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<a href="http://3.bp.blogspot.com/-Uwcfxlx2sqM/UtGlHBCIdsI/AAAAAAAAHdw/lNBqwRrTgXA/s1600/P1090578.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://3.bp.blogspot.com/-Uwcfxlx2sqM/UtGlHBCIdsI/AAAAAAAAHdw/lNBqwRrTgXA/s1600/P1090578.jpg" height="213" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> And prepare the stem for the new bearing.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Then I needed to tap the handlebar retaining bolt holes as these had not been protected from the powder coating.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> I also spent some time wire brushing up the original clamp bolts.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Then let's see where these bearings go.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> I think there should be a washer underneath that bearing.</span></div>
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<a href="http://3.bp.blogspot.com/-IZ9___vKBYc/UtGpgMics1I/AAAAAAAAHfA/JUC409DlTUs/s1600/P1090604-001.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://3.bp.blogspot.com/-IZ9___vKBYc/UtGpgMics1I/AAAAAAAAHfA/JUC409DlTUs/s1600/P1090604-001.jpg" height="213" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">I need to find a way of pushing this bearing right down to be in contact with the T section (including the washer which is not present).</span></div>
Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-5359243658365047442014-01-11T19:19:00.001+00:002014-01-11T20:41:04.402+00:00What's Been Happening <div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">Some time (nearly 4 months) has passed since I last posted. But fear not. My passion is undiminished. I decided that this project is unlikely to be on the road anytime soon. In fact I now estimate at least summer 2015. I have realised just how much time all this takes and how much money it costs. I have also realised that when it is finished, it will be so lovely, I will be very afraid of riding it out.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"><br />So to get around this I bought another GS1100G which will be my Road Runner. A bike I can ride around in all weathers and not worry about spoiling it.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">I started up another blog for her and you can see it here: <a href="http://suzukigs1100g1982.blogspot.co.uk/" target="_blank">Suzuki GS1100G Road Runner Project.</a></span></div>
Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-26445048880082401962013-09-04T21:32:00.000+01:002013-10-11T19:06:57.272+01:00Installing Head Races and Swing Arm Bearings<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">This is officially the start of the actual rebuild. This is the first 2 parts of the bike I am putting together. Up till now it has been all dismantling and preparation. Now we are rebuilding. </span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Now this might seem like a simple job - putting in the head races. Line them up and bang them in. I did this and the first one immediately went in sideways. So I stopped and decided I needed some expert help. A local bike mechanic has a very nice workshop and all the equipment and experience you need. So it was off over there. First we did the head races. Clean up the interior surfaces and make sure no powder coating is interfering with the fit (nice to have some help!).</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Nice and clean - ready to go.</span> </div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Then we put in the race and clamped it in the jaws of a 10 ton press.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Nice and easy does it. Why don't we all have tools like this?</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Now onto the swing arm. Using the other half as a bolster to make sure they are fully seated.</span> </div>
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<span style="font-family: Arial,Helvetica,sans-serif;">And back in the 10 ton press.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> In you go.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">And fully home.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> </span><a href="http://3.bp.blogspot.com/-tZaLVZ7qaHc/UieWkS_Vx5I/AAAAAAAAGf0/DMGnFcjBDIs/s1600/IMG_1011.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://3.bp.blogspot.com/-tZaLVZ7qaHc/UieWkS_Vx5I/AAAAAAAAGf0/DMGnFcjBDIs/s320/IMG_1011.JPG" width="239" /></a></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-14182720066558595602013-07-11T18:13:00.000+01:002014-01-11T20:37:48.795+00:00Frame Powder Coated<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">This is what we started with (click images to enlarge):</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Rusty, dirty and not so nice. . . . </span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">and this is what it looks like after powder coating with a satin black finish:</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> I am in love.</span></div>
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<br />Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-8465224879475489132013-06-30T22:02:00.000+01:002013-06-30T22:02:08.254+01:00Front Caliper (2nd one) Preparation for Painting<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">Despite my problems with the first caliper and some of the paint blistering, I am preparing the second caliper to start a new process which hopefully I can then reproduce on the first one. So to strip the caliper I am again using VHT Aircraft Strip (very expensive and eventually does the job after a couple of applications).</span></div>
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<a href="http://3.bp.blogspot.com/-7mA8wEfn9sc/UdCZWQi9hYI/AAAAAAAAFLA/SkuAWFZr-ls/s1280/P1070600.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="213" src="http://3.bp.blogspot.com/-7mA8wEfn9sc/UdCZWQi9hYI/AAAAAAAAFLA/SkuAWFZr-ls/s320/P1070600.jpg" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">On the first application you get this:</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Which you then wash off and it looks like this:</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">There is still quite a bit of paint to come off</span> <span style="font-family: Arial,Helvetica,sans-serif;">so put on another coat of VHT Aircraft Strip</span>:</div>
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<a href="http://2.bp.blogspot.com/-nBvKi-S3GDk/UdCa1fRL0GI/AAAAAAAAFLo/vUKAgj9gAFM/s1280/P1070605.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="213" src="http://2.bp.blogspot.com/-nBvKi-S3GDk/UdCa1fRL0GI/AAAAAAAAFLo/vUKAgj9gAFM/s320/P1070605.jpg" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Then wash it all off again and what I did was to put it in my Ultrasonic Cleaner with some Automotive Parts Cleaner solution for about an hour at 70 Deg C. When they came out and dried off you could clearly see why I am having a painting problem. This caliper was much worse:</span></div>
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<a href="http://2.bp.blogspot.com/-SYTSP2Y2OYo/UdCcSqYSFeI/AAAAAAAAFMA/MKqslBQ5wWc/s1280/P1070606.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="213" src="http://2.bp.blogspot.com/-SYTSP2Y2OYo/UdCcSqYSFeI/AAAAAAAAFMA/MKqslBQ5wWc/s320/P1070606.jpg" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> The oxidation on this part is severe. Vapour blasting it is.</span></div>
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<a href="http://1.bp.blogspot.com/-fdH6pVkKkR0/UdCcSgRcSQI/AAAAAAAAFMM/aqc2w1mFm9U/s1280/P1070607.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="213" src="http://1.bp.blogspot.com/-fdH6pVkKkR0/UdCcSgRcSQI/AAAAAAAAFMM/aqc2w1mFm9U/s320/P1070607.jpg" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> But on the other surfaces it looks OK. This is deceptive as the oxised parts will reject the paint.</span></div>
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<a href="http://3.bp.blogspot.com/-764hkCxgom0/UdCcSrPdUEI/AAAAAAAAFME/E8zrt6kPvao/s1280/P1070608.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="213" src="http://3.bp.blogspot.com/-764hkCxgom0/UdCcSrPdUEI/AAAAAAAAFME/E8zrt6kPvao/s320/P1070608.jpg" width="320" /></a></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-45830608021527221962013-06-28T16:41:00.000+01:002013-06-28T16:41:13.262+01:00Another Way To Get a Piston Out of a Brake Caliper<div class="separator" style="clear: both; text-align: center;">
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<span style="font-family: Arial,Helvetica,sans-serif;">I have managed to get pistons out of brake calipers before using the <a href="http://suzukigs1100.blogspot.co.uk/2013/05/rear-caliper-disassembley-day-275.html" target="_blank">air pump method</a> but this one wouldn't budge. My solution was to dremel a couple of slots in the side of the exposed piston and lever them out.</span></div>
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<a href="http://3.bp.blogspot.com/-eEmelYl2Q7E/Uc2t81vOfdI/AAAAAAAAFKY/_lWetRb_s7w/s1280/P1070493.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="213" src="http://3.bp.blogspot.com/-eEmelYl2Q7E/Uc2t81vOfdI/AAAAAAAAFKY/_lWetRb_s7w/s320/P1070493.jpg" width="320" /></a></div>
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<a href="http://4.bp.blogspot.com/-OWZOgRMkvjI/Uc2t84VmO3I/AAAAAAAAFKs/vJfeMxAeMzg/s1280/P1070495.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="213" src="http://4.bp.blogspot.com/-OWZOgRMkvjI/Uc2t84VmO3I/AAAAAAAAFKs/vJfeMxAeMzg/s320/P1070495.jpg" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Once the slots are in you will need to use something to lever the piston out. I used various sizes of allen keys to keep the slot at the correct height for levering.</span></div>
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<a href="http://1.bp.blogspot.com/-GPSAmeqJeeU/Uc2t8wv-RZI/AAAAAAAAFKc/ijjpn1SKyig/s1280/P1070496.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="213" src="http://1.bp.blogspot.com/-GPSAmeqJeeU/Uc2t8wv-RZI/AAAAAAAAFKc/ijjpn1SKyig/s320/P1070496.jpg" width="320" /></a></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-82470069475397736962013-06-27T21:23:00.001+01:002014-01-19T16:15:01.197+00:00Caliper Painting Problems (again)<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">Try
as I might to get these calipers painted properly. Always seems to
bubble up in certain areas. I bought an ultrasonic cleaner. I stripped
the paint again and cleaned them up in the ultrasonic then I applied
paint prep liquid (spirit based fast flash off) bought from a specialist
car paint place. Then I did the 3 coats of paint (as per VHT
instructions) and finally baked it in a 200 C oven for 1 hour.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> This was the painting part.</span></div>
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<a href="http://3.bp.blogspot.com/-h3m2vtsEObI/Ucyc-kqcDcI/AAAAAAAAFJI/HYiZy3U92TQ/s1280/P1070572.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://3.bp.blogspot.com/-h3m2vtsEObI/Ucyc-kqcDcI/AAAAAAAAFJI/HYiZy3U92TQ/s320/P1070572.jpg" height="213" width="320" /></a></div>
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<span style="font-family: Arial, Helvetica, sans-serif;">Looks quite glossy before curing in the oven.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> My painting garage.</span></div>
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<a href="http://3.bp.blogspot.com/-0Qdx86f1V1s/Ucyc-qtF5pI/AAAAAAAAFJU/0ncfh6IIDO8/s1280/P1070576.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://3.bp.blogspot.com/-0Qdx86f1V1s/Ucyc-qtF5pI/AAAAAAAAFJU/0ncfh6IIDO8/s320/P1070576.jpg" height="213" width="320" /></a></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> After curing.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Bubbles blew up in certain places.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">Looks like the lunar surface.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> But I have now got my suspicions. These parts where it has bubbled were where there was considerable oxidation. Although I had ultrasonically cleaned the caliper I do believe that this deep seated oxidation was not properly removed. I could still see some discoloration where it was obvious something was going on. I think next time (how many more times do I have to do this?) I will bake them at 200 C after cleaning and before painting. This might removed any moisture that is trapped in the oxidation.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">The bugger was that as I got them out the oven with some rubbish oven mits, I burned my hand, let go of the tray and dropped them on the floor. So I am going to have to do them again anyway! </span></div>
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Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-13829902725109727522013-06-19T20:22:00.003+01:002013-06-19T20:31:31.532+01:00Items Sent to Powder Coating (Day 305)<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">I went through all my boxes of parts, looked over the dismantling log and pulled out all the components I thought were capable of being powder coated. So I have the frame (click images to enlarge):</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">and a selection of other parts including the main stand</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> the side stand, swing arm, side stand bracket, top and bottom fork yokes, rear brake caliper bracket and the 2 front fork air balancing tube widgets</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> then there was the battery holder, ignition key set, horns, front wheel dust seal, air box side covers, speedo bracket, brake caliper arms, rear indicator arms, starter motor cover, horn cover (x 1 ??), electrics plate, handlebar clamps, exhaust bracket and a part next to the starter motor cover which I forget what it is.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;"> Then I have the helmet lock, seat lock, rear master cylinder and some bits I have put on other photos.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">I have requested the satin black finish. I tried to put in every conceivable part but you always forget something! I left behind all the triangular engine brackets and the other horn faceplate. Lets hope they won't mind doing a few little bits at a later date.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">When I got to the powder coating company they told me they could not do the items with the locks in them as they would be ruined by the process. They had previously told me that they couldn't do brake calipers either which is a shame as I will now have to persevere with the VHT paint.</span></div>
Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.comtag:blogger.com,1999:blog-1211283033632868459.post-82949333627060801572013-05-25T17:22:00.001+01:002013-05-25T17:28:49.159+01:00Carburetor Parts Plated<div style="text-align: center;">
<span style="font-family: Arial,Helvetica,sans-serif;">I just got my carb parts back from plating. This lot has been cadmium plated and here are the before and after shots. I will now be able to start the rebuild.</span></div>
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<span style="font-family: Arial,Helvetica,sans-serif;">These restoration projects are all about getting the little details done. Here they are done!</span><br />
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<br />Londonboardshttp://www.blogger.com/profile/02088919501239145613noreply@blogger.com