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Fitting the GS 1000 tank with an 1135 engine

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    Fitting the GS 1000 tank with an 1135 engine

    Having fitted an 1135 ( rebored to 1230) engine in my 1100 Katana, I decided to do the same upgrade on a GS 1000.
    It looked pretty simple as the carbs of the 1135 have the same outside dimensions as the OEM GS 1000 ET despite the increase of the throttle slide from 29 to 32 mm.
    The first difficulty came from the bottom front left frame lug that has to be moved out for to fit the larger engine.
    A pain as it's welded on the GS 1000...
    The next difficulty is that the petrol tank will slighly touch the top of camshaft cover as the engine is slightly taller.
    Here's a picture
    IMG_2917 small.jpg
    sigpicJohn Kat
    My bikes: CB 77, GS 1000 ST Cafe Racer with GSXR 1052 engine, GS 1000 ST, XR 41 Replica with GS 1085 engine,
    GS 1100 SZ Katana with GS 1135 EFF engine, KTM Superduke 1290 R 2020

    #2
    The solution is simple in theory as you only need to lift the tank.
    In this case, I decided to lift the front of the tank by 10 mm.
    To do so I drilled a hole above the normal tank support to insert an Allen bolt through the frame.
    Next, I "tortured" the rubber support so that the original hole was augmented in one direction to take both the original support and the protuding bolt.
    A bit of glue ensured it would stay put when installing the tank.

    IMG_2915 small.jpg
    sigpicJohn Kat
    My bikes: CB 77, GS 1000 ST Cafe Racer with GSXR 1052 engine, GS 1000 ST, XR 41 Replica with GS 1085 engine,
    GS 1100 SZ Katana with GS 1135 EFF engine, KTM Superduke 1290 R 2020

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      #3
      And the final product:

      IMG_2916 small.jpg

      I'll explain in another post how I did with a GSXR 1059 engine in a GS 1000 frame to solve the same issue.

      sigpicJohn Kat
      My bikes: CB 77, GS 1000 ST Cafe Racer with GSXR 1052 engine, GS 1000 ST, XR 41 Replica with GS 1085 engine,
      GS 1100 SZ Katana with GS 1135 EFF engine, KTM Superduke 1290 R 2020

      Comment


        #4
        John, thanks for the how-to and the pics.
        2@ \'78 GS1000

        Comment


          #5
          My pleasure Steve!
          By any chance if you bump into a throttle slide (32 mm in diameter) for a BS 36 SS carb please let me know .
          sigpicJohn Kat
          My bikes: CB 77, GS 1000 ST Cafe Racer with GSXR 1052 engine, GS 1000 ST, XR 41 Replica with GS 1085 engine,
          GS 1100 SZ Katana with GS 1135 EFF engine, KTM Superduke 1290 R 2020

          Comment


            #6
            Thats a lot cleaner than my version. I made a new bracket for the rear mount point, which helped me with petcock clearance issues. Had to make a couple new motor mounts also. Sorry no pics. It's been a very long time.
            Current Rides: 82 GS1100E, 00 Triumph 955 Speed Triple, 03 Kawasaki ZRX1200, 01 Honda GL1800, '15 Kawasaki 1000 Versys
            Past Rides: 72 Honda SL-125, Kawasaki KE-175, 77 GS750 with total yosh stage 1 kit, 79 GS1000s, 80 GS1000S, 82 GS750e,82 GS1000S, 84 VF500f, 86 FZR600, 95 Triumph Sprint 900,96 Triumph Sprint, 97 Triumph Sprint, 01 Kawasaki ZRX1200, 07 Triumph Tiger 1050, 01 Yam YFZ250F
            Work in progress: 78 GS1000, unknown year GS1100ES

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