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Another Aussie GS rebuild - GS1100G

  • Thread starter Thread starter JimmyR
  • Start date Start date
Registration inspection tomorrow morning. Today I tidied a few things up for the bureaucrats - put some side reflectors on because they like things that are shiny, put the big daggy mirrors on, and tweaked the pipes. When I started it this morning it was louder than usual with a bit of a raspy note. Turns out that the bit underneath the bike where the two halves of the 4-2 join (just before the mufflers) had spread a little so the connecting pipe was leaking a bit. So I loosened everything off, put the joiner pipe back in and tightened it up a bit. Also put some exhaust sealant on the join. Sounds a lot better, if quieter.

I've done everything I can think of to get this bike registered - I hope it passes!
 
Why is it that you can get everything working and it will work until you really really need it to? I had my rego inspection today. On the way there my exhaust decided to open up again just before the mufflers. I had fixed it, ridden it around and all was well until about 10 minutes before the inspection. Same thing with the indicators. Worked flawlessly until 5 minutes before the inspection. The front left and rear right decided they were tired. So my bike didn't pass. They also said my clutch wasn't disengaging enough.

Well that's ok. Now I know what I have to fix and it's all easy stuff. So I can get it registered next week. Sigh.
 
Look at it positively. Not only can you fix these things,
you got to ride it today! :)

Daniel
 
Funny you should say that Daniel - because that's what I said to my wife when I got back. It was really good to get in a decent ride on the bike for the first time. It's a really cool bike to ride and the guy at the inspection centre said "Nice bike - very sought after!". Although the clutch lever is heavier than I'm used to. The guy who inspected it was pretty cool really. He seemed to want to pass it but couldn't! I got the feeling it was his kind of bike.
 
Ok - so the exhaust is now definitely fixed:

underexh001copy.jpg


I'll probably end up wrapping parts of the exhaust. If not I'll do this again but chrome this bit. I have quite a bit of tubing left over.
 
JimmyR said:
The guy who inspected it was pretty cool really. He seemed to want to pass it but couldn't! I got the feeling it was his kind of bike.
Click to expand...

That would be a good sign. ;)
As for that cross-over tube, I would just paint it with Hi-Temp exhaust/engine paint and call it good.
Who, besides yourself, is going to be crawling under the oil pan?
The inspector might but that's about it. And it cannot really be seen anyway.

Daniel
 
High temp paint on the crossover tube? That's a great idea! Might just do that. Thanks! And yes, you really can't see it unless you are extremely short.
 
Exhaust is done, and the rear brake line is now secured. As I used Goodridge stainless braided lines and they are a fair bit narrower than the old stock lines the inspector wanted to see the line more secure along the swingarm. I had it running where the old lines went and I'm sure it was perfectly secure but he wanted it clamped tight. So I just bent the clamps down a bit more. Done.

So now all I have to do is fix the indicators - which I know I can do - and tighten the clutch cable and I'm ready to be registered.

Interesting tidbit - as my Shorai battery was still charging I used an ebay lithium battery to get to the inspection. Because it is tiny it was sitting on two spraycan lids inside the battery compartment so the leads could reach it! It worked perfectly and you can't see it while the side covers are on. Now that the Shorai is charged again it will be going back in.
 
Now I have fresh oil in there as well. Took the clutch cover off to give it a clean and get the gunk out of the glass oil level window. Adjusted the clutch to please the inspector. So now all I have to do is fix the indicators.

This is weird. The indicators worked all the time until the morning of the inspection. You can tell if one of the indicators is not working sometimes because the blinking speeds up. It never did that before! So I took off the front indicator that wasn't working and it's toast. The bulb is fine but the wiring is crispy fried. It's just old and impossible to solder to. Oh well, I put on my much nicer new indicators and hope the inspector likes them even though they're not stock.

So I guess it would be a good idea to put the matching indicators on at the rear, especially seeing as the stock ones aren't too healthy. In fact the rear blinker that is now faulty is even worse than the front one! I just don't get how they could work perfectly for so long and then fail the morning of the inspection. There are dark forces at work here.
 
The grounding ring and where it rides against the shaft plus the connector are problem area's with these young scooters.
I make them nice and shiny, better than new.

Daniel
 
Well I replaced all four indicators today. And they all work. Yay! I took it out for a ride to test the clutch, swish the new oil around and just shake some cobwebs out and it is running the best it has since I have had the bike. It must really like the new oil. Everything is working as well as I can imagine, having never ridden another Suzuki. I really like this bike. It's a lot of fun to ride! Very comfortable too.
 
Now, as soon as it is legal, you will be well on your way to searching for another "fix." ;)
They are addicting. :cool:

Daniel
 
Ah but I have a tricky way of avoiding having a collection of bikes - nowhere to keep them! It is already difficult having two bikes.

But I agree with you. It IS addictive. Anyway I'm off to the inspection centre again.
 
Back from inspection - registered!! Yay! Now I can really get stuck in.

Not sure my lovely little tacho is accurate. The bike seems to want to idle at 2000 according to my new tacho, but it seems very slow for 2000rpm. I think I'll plug in my old tach and see what it says. BTW on the way back from rego I did open it up a bit and yes indeed - it loves to rev! In normal riding I barely get up to 4500rpm but today I got it up to 6000 and it sounds amazing and pulls like crazy. Very impressive.
 
Pics from my little ride to the beach today:

PLsuz.jpg


BeachSuz.jpg


Nowhere near finished yet but I just had to ride it.
 
Hey Jimmy, where did you get the grips?
My sister is in Kalbarri, 45 at their place over the weekend.
PS. Looking good!
 
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