GS 1000 engine in GSXR 1100 first gen frame?

[John Kat]

The engine case finally got to me and in no time flat I had them positionned in the frame.
There is no big surprise except that there is still some work to do...
In fact the bottom rear of the engine case is just a little too wide to fit between the frame mounting brackets.
It must be a question of 1 or 2 mm each side that can be filed away.
As you will see in the pictures the engine is "attached" through the OEM front right upper mount.
Lenght wise it's almost bang on and within the latitude of my top frame extensions.

[John Kat]

I got the frame reunited today as I got the bottom rails extensions back from the machinist.
As you can see there is a little step in these to cater for the lowering of the front end.
Good news for the bike's geometry.
By the end of the week I should get some GS 1000 engine cases I bought from Germany.
Another good news is that upper case engine mounts will most probably be reusable.
That much less to machine!

[Carter Turk]

Got it! Enjoying the build thread and all the hurdles.

[John Kat]

I thought I heard it's not possible to join un matched case halfs, as they are line bored for the crank and transmission shafts.

Quite right but I'm only using them as a jig to finalyse the fitting in the frame.
I want to get the bike complete before transplanting the engine from my GS 1000 XP.

[Carter Turk]

I thought I heard it's not possible to join un matched case halfs, as they are line bored for the crank and transmission shafts.

sounds like you have a plan, keep posting progress

[John Kat]

looking good there john

are you going to cut and lenghten the downtubes to get the bottom tubes to line up ?
with cutting top rails and moving forward you are also moving up seems if you are lining up the tubes correctly you would need to do 4 cuts not 2

You are right, except that I will connect the downtubes through a small Z to avoid two further cuts.
In practice, it should be almost unoticeable.
In fact adding two more cuts would introduce further issues as the sloping portion of the downtubes is not parallel...
Here I've used the Keep It Simple adage to his fullest.

looking good there john

are you going to cut and lenghten the downtubes to get the bottom tubes to line up ?
with cutting top rails and moving forward you are also moving up seems if you are lining up the tubes correctly you would need to do 4 cuts not 2

[John Kat]

How long is it going to be for you to get a lower case for that engine????

Too long to my liking but I found one today here in France.
In the meantime, I've devised a jig to ensure the frame is straight when it gets welded.
Still have to have it built however...

[JTGS850GL]

How long is it going to be for you to get a lower case for that engine????

[John Kat]

A final test to see if everything fits before making the lower rail extensions.
There could be an issue with non-CV carbs but the engine will most probably sit a little lower in the frame.

[John Kat]

I got the upper frame rail extensions back for the machinist and luckily I got the two frame halves united again.
Next will come the bottom frame rail extensions but that's easy in comparaison.
I'm not too keen to get that done until I get a hold on a bottom engine case...
Here's the result so far:

Don't have any GS experience, only GSX. But as far as I'm aware the cases are pretty much the same. Should be good enough for mock-up purposes...

[John Kat]

Hey John,

just found this project thread. Do you still need that lower crank case? Bad conscience here...

Hi Pedda,
Don't worry, I know it's a pain to ship large parcels through the post.
I'm currently working another alternative here in France so let's wait to see if it works out?
As you have swapped engines back and forth, do you know if the GSX cases fit with no modification in a GS 1000.
I'll check with my Katana but would appreciate your input.

Hey John,

just found this project thread. Do you still need that lower crank case? Bad conscience here...