82 GS1100E Mr Turbo Rebuild

[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]

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.

 

[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]

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.

 

[dorkburger]

EPIC! One cannot share too many pictures of that nature. The history, and that its being passed on is beyond cool.

 

[dorkburger]

..... and I think the top of the fork damper rod is a 19mm 12 point. It was on my 1150. I welded a bolt with a 19mm head to a section of 1/2 steel pipe and used vice grips to hold it in place.
Some have had success just hitting the allen bolt on the bottom with an impact gun and having it loosen without needing to hold the top end back.

 

[steve murdoch]

I agree. Bomb away!
He must so happy finding you as the buyer. Someone that will honour his achievements and his bike.

 

[oldGSfan]

Tried the impact and I can see it spinning, it's a round hole, hence that special tool, a tapered 4 point spear like thingie that msut gouge into the aluminum. Why they changed I don't know. RaceTech makes one that is just round - https://www.racetech.com/page/id/70 on left. I'll figger it out, thanks everyone.

..... and I think the top of the fork damper rod is a 19mm 12 point. It was on my 1150. I welded a bolt with a 19mm head to a section of 1/2 steel pipe and used vice grips to hold it in place.
Some have had success just hitting the allen bolt on the bottom with an impact gun and having it loosen without needing to hold the top end back.

 

[oldGSfan]

Yeah he said he was glad I was noting the history, taking photos.

Couple of time slips and a friend that ran a nitrous GS maybe a member

I agree. Bomb away!
He must so happy finding you as the buyer. Someone that will honour his achievements and his bike.

 

[posplayr]

Very cool pictures and history. Best part the guy is still alive and can appreciate your effort to keep it alive rather than have everything just dumped on ebay.

 

[oldGSfan]

Also got a pile of paperwork, manuals, receipts and these cool old posters and a program from Bonneville in the 80's.

 

[posplayr]

That 81 EX with Nitrous bottle looks scary on stock forks.

I like the paint, I repainted by GS750EX that color.

 

[oldGSfan]

Well, the bike I got has stock forks and did 183. The shocks were shortened, I have the receipt from Don Vesco. Fork has progressive springs, other than that, factory. There was very little oil in them, and they were very spongy. Seller said that on El Mirage dry lake it was like riding on ball bearings.

That 81 EX with Nitrous bottle looks scary on stock forks.

I like the paint, I repainted by GS750EX that color.

 

[oldGSfan]

Today I got moving on the engine, I cleaned up the the spark plug hole areas then removed the plugs, cleaned a bit more and put a tablespoon of oil in each cylinder yesterday. I de-grunged some areas that had a buildup of fuel varnish (?) with carb cleaner and a pick, and taped off all openings for the next stage of de-greasing and power washing. I turned engine and there was no problem, it's moving freely.

On the polishing front, I have have started with 500 on the sprocket cover after removing the clear coat with paint remover. There's not much in the way of corrosion or gouges so they will come out great - I'm having deja vu from my '82 Katana refresh, which I added in the last photo below.

 

[oldGSfan]

My son likes to show me Turbo 'Busa stuff on Instagram. I told him this is a Turbo 'GooSa', it's grandpappy. Might surprise one of those guys someday on this thing. Previous owner said he dropped it to 4th at 150 and lofted the front end high ... I'm too old for that. My son says he's up to the task, OMG what have I done, corrupting impressionable 15 y/o minds.

Found water injection tank and a big honkin' AC Delco pump. Right now I've got cases, calipers, frame and engine prepped or prepping. I think I'll leave the frame be, not powder coat as I thought. It's so good, just a few spots to touch up, and I think I can blend in VHT rollbar and chassis paint on the down tubes which are the only visible part. That and treat/paint the non visible areas that have a bit of rust from the salts.







Either way the little bit of corrosion in the non visible areas will be dealt with. Normally I wire brush, then put some r

There's something about original finish that appeals to me

 

[oldGSfan]

I got a very cheap Harbor Freight blaster and tried it out with some baking soda. Gravity feed probably better, I looked at the CFM needs and picked the lowest due to my wimpy compressor. It made quick work of the brake calipers, and my teeth are much whiter too! I'll use on the engine (with everything sealed tighter than a frog's butt). I just have to be patient or borrow a bigger compressor, as mine is still too wimpy.

 

[Spyder]

Wow, those came out nice. Which HF blaster did you get? I have been considering buying one, but have been waiting for someone else to take that plunge, then evaluating their results, LOL.

 

[oldGSfan]

https://www.harborfreight.com/1-liter-abrasive-blast-gun-92857.html. Lots of videos about making something similar out of a plastic bottle and a tube type air gun but that looked like too much fiddling. I got a disposable plastic inline dryer for another $3.

Wow, those came out nice. Which HF blaster did you get? I have been considering buying one, but have been waiting for someone else to take that plunge, then evaluating their results, LOL.

 

[oldGSfan]

Got my bench grinder set up with buffing wheels and had a pass with the Tripoli after sanding down the few gouges, coming along nicely. Got all engine covers and footpeg brackets pretty much done, except some Dremel work and maybe touch up. I don't want to overdo it. Rainy day so I couldn't soda blast or paint.

 

[Spyder]

https://www.harborfreight.com/1-liter-abrasive-blast-gun-92857.html. Lots of videos about making something similar out of a plastic bottle and a tube type air gun but that looked like too much fiddling. I got a disposable plastic inline dryer for another $3.

Well alright, thanks for the tip. I will likely pick one up for next winters painting projects.