GS1100G Cafe Racer

[Guest]

Hmmm... that link didn't work...

http://www.boulevardsuzuki.com/fich...y=Motorcycles&make=SUZUKI&year=1982&fveh=2157

The piston set which appears to be both pistons and seals is $32.33...

 

[Guest]

my memory is not necesarrily that flash lol but i also *think* to remember that they were stainless steel pistons

My memory regularly masquerades as a sieve

 

[Guest]

AHA ! gottya !
http://www.wemoto.com/bikes/Suzuki/...tainless_Steel_Piston_and_Seals_Rear_Caliper/

 

[Guest]

does that link work?

http://www.wemoto.com/bikes/Suzuki/...tainless_Steel_Piston_and_Seals_Rear_Caliper/

 

[Guest]

Both those links work

That shows 80/81 though, isn't this an 83? No idea if there's a difference though coz my 450 has a drum

 

[oohsam]

Today was a total bitch of a day on the bike.
I've got the forks all disassembled, ready for the rebuild with progressives. Spent a good 2 hours cleaning the inner fork tubes and repainting the lower fork tubes. The first time I painted them, was a bit of a rush job...

I also decided to fit my new EBC clutch kit. Upon removing the existing clutch, I noticed that the current clutch is actually in pristine condition. All measurements were up to spec, So I decided to keep the curent clutch, and save my EBC kit for another day.

I also fitted the the clutch engine cover. I've replaced all the engine bolts with SS hex bolts, but they wouldnt drive in all the way.
I stuck a little screwdriver in there to see, and there was some bouncy resitance in the thread...strange.
Kept poking for about 20 mins, and I managed to get out a little rubber silicon piece about 5mm in length.
It looks like the PO used shorter bolts and filled the holes in silicone. I'm thinking it was liquid gasket and its the remaining residue that got onto the screw(s) and dried up inside the thread. Every screw had this issue and it took me 2 hours to clean it all out.
Pain in the ass. But its done now and the hex bolts tighten up nice now.....what a ****ty ****ty job....anyway its done now!

 

[Guest]

What a PITA! PO's do the strangest things at times, but glad you got it sorted

That clutch cover has a real nice shine too

And I think you dropped an exhaust gasket under the rear of the frame there...

 

[oohsam]

Thanks Pete. You know, I was reading over my posts, and You compliment my work alot but I never ever thank you! So here is a big Thank You for the nice stuff you say lol.
Sorry for 'ignoring' you. Was not on purpose at all!

Those damn gaskets -> I bought a set, for like 10 bux, then when I bought a gasket set, it came in them, then when I ordered a gasket for the clutch cover, I got another set...now they are just annoying me! haha..

So, I got the rear brake pistons, PeterStevo's ended up being able to get a set in for me, for like 40 bux. Which is only 8 dollars more than in the US. So it was ok.
I had to order some other stuff from them anyway so it was no biggie. Came in 1 day.
To my surprise, the PISTON set that is listed on the fische, includes

2 x Pistons
2 x dust seals
2 x Piston seals
2 x bleeder seal

I was surprised that it came with all the bits needed for a rebuild! happy bout that.
Put it all together...with some new brake pads. Came up ok...

Then fitted and bled the brake line. Took all of 15 mins. Dunno why the rear brake line I ordered (which came in a set from Goodridge), is freakin really long. Maybe I got it mixed up with the brake line that goes from the front master cylinder to the Splitter (before going to my front brakes)....its a bit shorter, but I think a little too short.

Meh, I just loopedy loop and cable tied it down. Should be ok.

Was glad that the piston seals etc. didn't leak...Looks ok me thinks.
The rear brake is highly over rated anyway, I rarely use it.

Also got new plugs, oil filter and some other bits and bobs for the bike. Plan is to get the wiring finished off this weekend, filler up with oil, and give her a crank.
Any tips for starting the bike after its been sitting for months...spesh since there is no oil in the engine. Do i have to crank it a bit first to get the oil through or whats the deal?

 

[Leigh]

Dunno why the rear brake line I ordered (which came in a set from Goodridge), is freakin really long.

Same thing happened to me.
I got Goodridge front lines in for the 750 that were way too long.
I could have wrapped them around both fork legs.

I sent them back.
There is a joint in Braeside called Better Brakes who will make up and fit the lines on the spot and they are a third of the cost of Goodridge.
Plus they are ADR approved.

 

[oohsam]

For real, awesome ill look em up!

 

[FLHGSRay]

Mind you, wait 'til I correct you with the word "thongs" and see what the US guys think of that... hahaha

Some of the less experienced (haven't fallen down yet) riders around here call those riding boots.

 

[Hoosier Daddy]

Being a shafty yours may be laid out different than mine but...
My brake hose extends further back then up to the caliper, looks like a bracket should be on your axle pinch bolt for the hose then the hose would come up the back side of the caliper to the banjo bolt.
Once again, comparing apples to oranges but that would take care of your excess hose length.

 

[morrison]

What are your plans on wiring in the Vapor dash?>?

 

[Guest]

Mate it's all good, but thanks for the thanks for the compliments... haha

I'm just lovin' this build is all

I was going to say I think your brake hose should go around the rear from others I've seen, but Hoosier beat me to it...

And yeah, my piston set for my front caliper included the dust seal, piston, and piston seal as well, so I think they really should've called them rebuild kits because nothing else is needed...

FLHGSRay: Some here do too now that you mention it... and full gear includes T-shirt and stubbies

 

[oohsam]

Thanks Guys,
It seems as though my rear brake is not off a GS1100G, it's of another GS but not sure what model, as the banjo bolt location is on the bottom, whereas, the others (like bikeboys) is round the top, so the cable spins round up there.

Still works the same, and has the same parts, other than that, and only having one bleeder (the real GS1100's have 2) thats all I can see, and thats why I have so much slack.

Will probably get a shorter one in good time (but not on my urgent list).

Morrison -
I've already wired up the Dash, it just needs to go on, You will see more on this topic in the next few days
It's a piece of cake to wire up. The only thing I didn't like, was that it had a shared earth for all the accessory lights. This sucked, as the Oil Pressure switch is activated by earth, so I had to do some cutting and soldering on the unit to get it to work.

 

[Leigh]

Some of the less experienced (haven't fallen down yet) riders around here call those riding boots.

 

[oohsam]

This mod serves no purpose other than to look cool and provide me with some useful statistics on my oil pressure...

Its as easy as this.
Remove this bolt..

Install this

Then adjust to your desired angle...

Lets hope there is oilpressure when it fires up again... :O

 

[Hoosier Daddy]

Oh now I can hardley wait to see where my oil port is located because I don't have the one you show... good stuff though!

 

[Guest]

Nice one! I'd love to do something similar except the bolt I can use on the 450 is located at the bottom of the right case cover, so I'd have to do some fancy routing to make it visible while riding...

 

[Flyboy]

Wow, coming on nicely, that is looking super sweet, you have done some really nice work there, I like.
Yeah, the brake line goes around the very back of the swingarm, if you look at the very back, you will see a threaded hole for a 5mm bolt that hold the bracket that secure the line.

Starting up is a breeze, remove all the spark plugs, so there is no compression, and the motor can spin nice and quick, and not fire up, turn on and turn it over on the starter until the oil light goes out, and your fancy new gauge (I like) shows a steady pressure.
Put plugs back in and fire her up.
Keep idle down nice and low, but not too low while she warms up, around 1200rpm or so.
We need a video