GSX1100ET - rebuild from boxes

[hampshirehog]

The 1100 turned up today, all in bits. Unfortunately the cleaning / paint was done about 6 years ago and everything needs doing again. Here's the bits:

Front fork legs gives an idea of what things are like:

So the forks got new slides:

and damper piston rings:

The legs got a polish, new fork seals and new Progressive springs.

 

[hampshirehog]

Then I thought I'd have a go at tidying up the front wheel. The alloy was pretty badly corroded and it took a while with steel wool followed by 1200 grit wet and dry and then Solvol Autosol. Looks pretty ok now - I'll give it another buff up when my arm has recovered.

 

[hampshirehog]

Both front discs were pretty rusty and the paint was flaking off. The outside of the discs got the wire brush treatment and the painted bits were girt blasted and sprayed with VHT satin. Cleaned up the bolts and tab washers too:

after:

 

[hampshirehog]

Rear wheel was in the same state as the front with the added bonus of 30 years of chain oil splatter. It and the disc got the same treatment as the front:

after:

 

[raerickson]

Looking really clean! Keep it up

 

[IT-simon]

Nice, i have to do the same

 

[Agemax]

looking good mate, keep up with the elbow grease, if you want some proper polishing done give me a shout lol

 

[1100E]

Oh boy, doesn't that look familiar. My '80E was apart like that just a few weeks ago, you have a load of work ahead of you but it's the best part of the rebuild. Try to have some fun while you're at it, the end result is definitely worth it. Looking good!!

 

[hampshirehog]

Sprayed the front brake calipers with VHT caliper paint (satin black) and fitted with new seals and boots:

Stainless pistons too - wearing their boots before fitting. As they're stainless they don't need the boots but what the heck:

All the steel bits were remarkably rust free - the caliper asles, pad guides and springs cleaned up like new.

 

[1100E]

I see a pile of OEM goodies like this in your future

 

[Wallowgreen]

Looking great mate, watching with interest keep the updates coming.

 

[radar]

I see a pile of OEM goodies like this in your future

I love those red and white labels with bar codes

 

[hampshirehog]

Rear caliper was in a pretty crappy state:

I didn't get so lucky with the caliper pistons (badly pitted) so got some for a Gixxer - no rings to fit the boots but as they're stainless they'll be fine. Goes without saying new seals:

And the rear MC was just as bad:

So it got a rebuild kit - genuine Zook of course:

 

[hampshirehog]

Rear MC fully rebuilt and sporting a fresh coat of paint (the blob on the top is a raindrop - first rain here for a while):

As I'm replacing all that 30 year old rubber might as well replace these - even though it shouldn't need air in the forks as it's bouncing on Progressive springs:

Might as well have new headrace bearings as well - here's the lower. Took a fair bit of getting on:

 

[Agemax]

looking good mate, what paint did you use on the bits and pieces?

 

[Turtleface]

looking good mate, what paint did you use on the bits and pieces?

VHT Satin Black caliper paint. Used the same stuff on my brakes as well.

 

[hampshirehog]

Front master cylinder looked like it might be a throwaway, especially as the piston was really jammed in there - it really took some getting out! Surprisingly though the bore was fine:

Question: why does the rear MC rebuild kit come in a box whereas the front comes in a bag?

 

[hampshirehog]

Frame picked up from the powder coaters. I've lost count of how many frames these boys have done for me over the last 25 years or so but it's perfection every time.

Thought I'd bolt a few things together and as the sun was shining go for a (very short and slow) ride:

And here it is from the other side - showing off my son's new car. He's on L plates so if you see it coming clear the road....

 

[hampshirehog]

Been putting off tackling the carbs - what mysteries lurk in there? The carb bodies weren't in too bad a shape - this is after a very quick clean:

The tops and float bowls were pretty corroded - they'll be getting a lot of work to polish up.

Just as I thought, the jets and screws were all really stuck in and there were a few small bits missing. I might be begging on here if I can't find the stuff in my garage.

All the rubbers were completely perished / gone hard. A good job we've got Robert Barr looking after us. Spot the mix of BS and VM O rings - lucky for me he labels everything so clearly: