Thanks Salty_Monk and dorkburger for your comments. Been a tough few days of soul searching and deliberations. I did say at the start it was a long term project.
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GS(X)1100ESD Long term project.....
- Thread starter Suzuki Mad
- Start date
G
Guest
Guest
The good thing about long-term projects is that there is no great pressure to get it finished. It's not like you need it to get to work on Monday morning. I bought a TS250 a while back - turned about to be a mix of two different models. My approach was to make a good job of the frame, then to work on sub-assemblies as and when time and funds allow. Lots of unobtainable parts, so I've made a list of part numbers I need to keep the project going - this gets checked against E-Bay, CMSNL, Facebook groups etc regularly. A second list is items that would be useful, but I don't actually need yet - these get bought if I see them at a reasonable price. Don't get discouraged - Suzuki were good at using the same parts on lots of different models. Or equally just send the project to me. I'll finish it sometime this decade....
Cheers steveb922.
At the moment I'm still at the assess stage. Need to hear the engine run, hear if its got rattles and knocks and whether its a reliable lump in its current condition. A rather a lot of money can get thrown at that bit so if its a non runner or needs loads of work like my last one did it's probably not going to get done.
I guess the down side is 3 of my bikes all use the same callipers front and rear. With the parts now becoming scarce it's going to be harder to keep them on the road.
Another part of me is why couldn't I have found this one back in 2004 when I started looking for one? It was less than 20 miles from my home tucked away in a shed. That's one of those things I will have to make peace with.
At the moment I'm still at the assess stage. Need to hear the engine run, hear if its got rattles and knocks and whether its a reliable lump in its current condition. A rather a lot of money can get thrown at that bit so if its a non runner or needs loads of work like my last one did it's probably not going to get done.
I guess the down side is 3 of my bikes all use the same callipers front and rear. With the parts now becoming scarce it's going to be harder to keep them on the road.
Another part of me is why couldn't I have found this one back in 2004 when I started looking for one? It was less than 20 miles from my home tucked away in a shed. That's one of those things I will have to make peace with.
G
Guest
Guest
I had a brief glance at Robinsons website, and it seemed to me that most of the seals, boots etc for GSs of that era were still available. Not necessarily as a kit, but as single items.
Keep after it & it'll come around
This one will be fun to sort.
Head off or in frame?
This is when I wish I had a welder, washers and nuts here. I'm not brave enough to drill it out myself. Done that, got the T shirt and people show videos on youtube of what I would end up with if I tried and they are fixing.......
Head off or in frame?
This is when I wish I had a welder, washers and nuts here. I'm not brave enough to drill it out myself. Done that, got the T shirt and people show videos on youtube of what I would end up with if I tried and they are fixing.......
Had a productive drive today.
Picked up a small part of the bike that I needed.
Now I can make a rolling chassis, that will make it easier to move around and give me more access when I need it.
Picked up a small part of the bike that I needed.
Now I can make a rolling chassis, that will make it easier to move around and give me more access when I need it.
Chatted with my 'Bro' this morning. He's a fabricator/welder of some 30 years experience (retired now) and he saw on reason why the Swinging arm lug thats missing and the crack in the mudguard couldn't be sorted easily. Just need to clean them up and take the to the local welder.
Had a play with the header bolts. I know 1 is snapped so the headers will have to come out to give access whether its a weld a nut job or drill out action. I'm pleased to announce that all 7 bolts came free easily!!!!!
I then pulled the carbs off the bike. Stripped them down with little fuss. Petrol inside smells like varnish but they were very clean. The jets and tubes are blocked so its likely she didn't run at all. I did 'lose' a float needle due to me forgetting to remove it from the housing before trying to pull the housing from the carb. Shot it about 6ft away behind the chest freezer so had to pull that out to find the missing part.
The down side of the day was I couldn't get the top rail off the carbs so I can give them a good ultrasonic bath. Even with a JIS bit in the impact driver they just wont come out. Going to try a bit of heat tomorrow and failing that it's more drastic of trying a hammer and punch to see if I can knock them out. Just hope that I dont snap any off as finding these carbs is like finding rocking horse poo.
On another down side I ordered a new battery for the bike. All looked good as I have bought from these people before. Ordered online, site showed stock. Following morning I get an email saying they are out of stock and they will get a new delivery in 7/10 working days.
Had a play with the header bolts. I know 1 is snapped so the headers will have to come out to give access whether its a weld a nut job or drill out action. I'm pleased to announce that all 7 bolts came free easily!!!!!
I then pulled the carbs off the bike. Stripped them down with little fuss. Petrol inside smells like varnish but they were very clean. The jets and tubes are blocked so its likely she didn't run at all. I did 'lose' a float needle due to me forgetting to remove it from the housing before trying to pull the housing from the carb. Shot it about 6ft away behind the chest freezer so had to pull that out to find the missing part.
The down side of the day was I couldn't get the top rail off the carbs so I can give them a good ultrasonic bath. Even with a JIS bit in the impact driver they just wont come out. Going to try a bit of heat tomorrow and failing that it's more drastic of trying a hammer and punch to see if I can knock them out. Just hope that I dont snap any off as finding these carbs is like finding rocking horse poo.
On another down side I ordered a new battery for the bike. All looked good as I have bought from these people before. Ordered online, site showed stock. Following morning I get an email saying they are out of stock and they will get a new delivery in 7/10 working days.
Saturday evening update.
This is where I am.
Rear end together just waiting to go back on the bike.
Front end waiting to go on.
Carbs stripped as far as I can get them for the moment.
Rear brake now off the holder. Waiting for seals to arrive.
In the box is a good left side calliper plus a few spares to go on once cleaned up and sorted.
With the new forks the anti-dive bleeders are free as with the new front Left calliper so only the front right calliper bleeder is the issue.
New parts to collect monday to sort the rear end going back in and I can refit the rear end, front end and the biek is ready to roll. Just brakes to sort and she can be stopped too.
This is where I am.
Rear end together just waiting to go back on the bike.
Front end waiting to go on.
Carbs stripped as far as I can get them for the moment.
Rear brake now off the holder. Waiting for seals to arrive.
In the box is a good left side calliper plus a few spares to go on once cleaned up and sorted.
With the new forks the anti-dive bleeders are free as with the new front Left calliper so only the front right calliper bleeder is the issue.
New parts to collect monday to sort the rear end going back in and I can refit the rear end, front end and the biek is ready to roll. Just brakes to sort and she can be stopped too.
Is that Metzeler ME99A tire? Would be funny to see the date code on that tire.
Think they were radials too way back then.
Think they were radials too way back then.
Yep, they are both front and rear.
Sorry no date code for the tyres I can see. Probably too old for date codes to be on bike tyres. I can say that whoever put them on was riding on the cheap. These are the H rated tyres not the V it should be.
Nearly as bad as my GS1000E project bikes tyres.....another blast from the past.
Pirelli Phantom 1's, ribbed front, squireled rear. I always used Pirelli back in the days of these bikes being new never Metzelers.
Sorry no date code for the tyres I can see. Probably too old for date codes to be on bike tyres. I can say that whoever put them on was riding on the cheap. These are the H rated tyres not the V it should be.
Nearly as bad as my GS1000E project bikes tyres.....another blast from the past.
Pirelli Phantom 1's, ribbed front, squireled rear. I always used Pirelli back in the days of these bikes being new never Metzelers.
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As it was first day of UK lockdown restriction being lifted I drove over to collect a few spares that were too large to post. Also was a good time for my daughter to practice driving. With that being the case spent only a short time in the workshop.
Swift work of removing the headers to give access to the sheared off head bolt.
Its not dead flush but close on. As so and so to get at with a punch and hammer to try and knock it out.
Whipped the front callipers off, not before loosening the pipework and also the slide pins that were seized solid.
Not sure what came out was blood or very old and nasty brake fluid.
Even my hand got in on the act.
Think tomorrow will be sorting out front brake and the front master cylinder so that there are working brakes for when I have to move the bike.
I've been asked why and the answer is I need that bushing done and the guys need the engine and frame to do it. Its a dam site easier to move the whole thing than as bits. The engine can be pulled apart later once its been heard running which is a few days away as I'm waiting for a battery and a few bits for the carbs. When I do the carbs I will post a bit about it.
Swift work of removing the headers to give access to the sheared off head bolt.
Its not dead flush but close on. As so and so to get at with a punch and hammer to try and knock it out.
Whipped the front callipers off, not before loosening the pipework and also the slide pins that were seized solid.
Not sure what came out was blood or very old and nasty brake fluid.
Even my hand got in on the act.
Think tomorrow will be sorting out front brake and the front master cylinder so that there are working brakes for when I have to move the bike.
I've been asked why and the answer is I need that bushing done and the guys need the engine and frame to do it. Its a dam site easier to move the whole thing than as bits. The engine can be pulled apart later once its been heard running which is a few days away as I'm waiting for a battery and a few bits for the carbs. When I do the carbs I will post a bit about it.
Started to remove the front end. Micron fork brace was fun to get off.
Any idea what this might be and its Suzuki part number?
Any idea what this might be and its Suzuki part number?
Here's a better view with the fork out and on the bench for closer inspection.
Is that a rag you found under the dust boot?
Good question and the answer is, I'm not sure. Looks like stuff you would use in a stern gland on a boat or that you'd pack water valves with to make them water tight. It's been in there 24 years so it's had it time. Guess somebody had a leaking fork seal and found a way to hold it up and keep riding.
The tubes are badly pitted but I was seeing how much of the lower leg could be saved and reused.
After a long day playing for forks and strange things lurking, sorting out what can be kept, what has to be sent away for restoring plus checking fleabay its come to that time.
Carb bath time.
Firstly, thanks to Londonboards who walked me through cleaning carbs last year. With my new toy, an ultrasonic cleaner, its time to start. Filled it up, started it off and popped off to have dinner. Came back and did carb one.
As you see a tub and 2 plastic bags for the carb and bits. Into the bath go the big bits and the smaller bits into 2 glass jars to be cleaned at the same time.
Gets a bit toasty in there. That fluid if from one carb by the way.
The one big issue was that all three of the synch lobes and springs were seized solid in the carb.
A small bit of tapping with a small dift onto a solid hammer head and that knocked them free. I had to remove the synch screws to get the lobes and springs out, clean the holes they fitted and gave them a little lubrication so now they move freely.
Worked through each carb cleaning and sorting as I went.
All bagged up, clean and lubed ready to have there new O rings fitted, a little grease where needed and new black stainless screws to replace the originals that were chewed up getting the rails apart. I will check the jets and all there little passages are clear tomorrow so may well have the cleaner out again to give them a bit more of a clean and going over. But it's looking good so far.
Carb bath time.
Firstly, thanks to Londonboards who walked me through cleaning carbs last year. With my new toy, an ultrasonic cleaner, its time to start. Filled it up, started it off and popped off to have dinner. Came back and did carb one.
As you see a tub and 2 plastic bags for the carb and bits. Into the bath go the big bits and the smaller bits into 2 glass jars to be cleaned at the same time.
Gets a bit toasty in there. That fluid if from one carb by the way.
The one big issue was that all three of the synch lobes and springs were seized solid in the carb.
A small bit of tapping with a small dift onto a solid hammer head and that knocked them free. I had to remove the synch screws to get the lobes and springs out, clean the holes they fitted and gave them a little lubrication so now they move freely.
Worked through each carb cleaning and sorting as I went.
All bagged up, clean and lubed ready to have there new O rings fitted, a little grease where needed and new black stainless screws to replace the originals that were chewed up getting the rails apart. I will check the jets and all there little passages are clear tomorrow so may well have the cleaner out again to give them a bit more of a clean and going over. But it's looking good so far.
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Just distilled water.
A little bit more progress.
My hands have been bad the last few days with cracking, being sore and bleeding so I said I wouldn't do any work on the bike today. I ended up doing some electrical work.
Jury rigged a battery....
Didnt check anything just turned the key....
got life out of her. No horns as none are attached but both are dead so I need new ones. Sadly these items are discontinued at Suzuki so I will have to find an alternative. Tried the indicators....
One worked the other didnt but that was because I had pushed the bullet connector into the wrong connector.
Got it right second time around. I did label them up after getting both right and left side to come on. Issue is I cant get the to blink, so its a control unit which I have a spare here or the relay.
Lights didn't work but that wa due to dead bulbs. Brake lights worked fine. Its questionable about the side stand switch. Didnt check for spark but should have done. I do know that she spun on the starter fine. No odd noises or 'orrible valve crashes. Get the carbs back together when I have some nitrile gloves, refit and add a bit of fuel........hopefully she will fire up and run.
My hands have been bad the last few days with cracking, being sore and bleeding so I said I wouldn't do any work on the bike today. I ended up doing some electrical work.
Jury rigged a battery....
Didnt check anything just turned the key....
got life out of her. No horns as none are attached but both are dead so I need new ones. Sadly these items are discontinued at Suzuki so I will have to find an alternative. Tried the indicators....
One worked the other didnt but that was because I had pushed the bullet connector into the wrong connector.
Got it right second time around. I did label them up after getting both right and left side to come on. Issue is I cant get the to blink, so its a control unit which I have a spare here or the relay.
Lights didn't work but that wa due to dead bulbs. Brake lights worked fine. Its questionable about the side stand switch. Didnt check for spark but should have done. I do know that she spun on the starter fine. No odd noises or 'orrible valve crashes. Get the carbs back together when I have some nitrile gloves, refit and add a bit of fuel........hopefully she will fire up and run.
