GSX1100EZ - GSXR and Bandit Upgrade

[ozgs]

Hi Guys,

I have used the time off over the Christmas break to finally get started on a project that I have been collecting parts for over the last 12 months. Before I start describing what I am up to, a big thanks to those that have contributed so much knowledge in this forum that make it much easier for people like me to get started on projects like this. The project has been inspired by those of Kichigai, Katman, Isloman, Posplayr, 80GS1000, and countless others that have contributed information. Hat?s off to you gentlemen.

This project really started by accident. I was searching for an engine and swing arm for my Cooley GS1000 project. Over here in Aus, these can be pretty hard to come by, so I thought I may have more luck slotting in a 16 valver. I ended up buying a complete 1982 GSX1100EZ from the local bike wreckers. I initially searched GS Resources to identify how to fit the 16 valver to the GS frame. This was when I found the great work that the above-mentioned have done and was inspired to go down a different path.

This bike had been partially restored, and had a very solid engine, but was sporting some horrible mods such as a grim reaper mural, Maltese cross mirrors etc. You get the picture. The only issue with the engine was the usual oil weeping from the front of the head gasket. I ultimately plan to reuse only the engine, frame, tail and headlights, battery box, starter solenoid and RH side panel. I have purchase a NOS ducktail, and second hand tank. I still need to track down LH side panel. I will probably buy a NOS side panel and have the paint colour matched to that.

I am probably not doing much that hasn?t been attempted before by anyone on these forums, but will be completely rewiring the bike using an electronic control module. The only ones that I have found to date are the Ultima and Motogadget M-Unit.

This is the list of parts sourced so far.

1994 GSXR1100 Forks
1993 Lower triple clamp
GSXR1100W Upper triple
Bandit 12 front wheel
1994 GSXR1100 Speedo drive
Early 90?s GSXR750 front axle
Early 90?s GSXR750 Tokico 4 Spot Calipers
Bandit 12 Swingarm
Bandit 12 rear axle and spacers
Bandit 6 Rear Caliper Mount
Katman shock mounts and top hat spacers

Parts still to be sourced:

Gauges (bandit 12, Koso, GSXR1100/750?) would like to retain analogue tacho
Front fender (GSXR) front discs
Racetech Fork Springs
Bar risers (or replace top yoke with ABM or similar)
Ignition Switch (GSXR)
Handlebars (like the Easton if retaining top clamp, otherwise superbike bars)
Handlebar switches (late model Suzuki?)
Kevlar Brake lines (HEL or Earls)
Rear calliper and torque arm (bandit)
Rear Master Cylinder (dependant on foot pegs used)
Rider and pillion footpegs and rear brake master cylinder (considering ZRX1200)
DID ERV3 Chain
520 Sprockets including 5/8 front offset 17/48 ratio
Tyres (Pirelli Diablo if 180 rear, otherwise a 170?)
LH Side Cover (tabs broken on original)
Front Master Cylinder (nissin radial oem, accossato or brembo radial)
Dyna S or 2000
Dyna Coils and leads
Rear shocks (would like Ohlins of course, but budget may dictate YSS, Gazi or Hagon)
Wiring control unit - motogadget or ultima
Compufire Regulator/Rectifier
Indicators
Bandit speedo cable
Billlet headlight brackets

Fabrication to be completed:

Weld shock mounts
Frame Bracing
Move Battery Box mounts higher in the frame
Fab new mounts for foot pegs
Fabricate or mod chain guard
Make custom wiring harness
Powder coat frame, triple clamps (and maybe swing arm)

Other work to be completed:

Paint body work
Replace fork seals
Rebuild callipers


I am currently dry fitting everything prior to sand blast and powder coat. Would love to get some feedback as things progress. Pics to follow.

Jon.

 

[ozgs]

I have fitted the swingarm to the frame using Katman's top hater spacers. I have also transferred the cush drive rubbers from the GSX wheel (complete with silver overspray, courtesy PO). The bandit wheel came without any hub or rubbers. Amazing how there is twenty years between the manufacture of these parts, but everything is so interchangeable. I will also be reusing the GSX hub. Previous research indicates that this brings the centreline of the sprocket approximately 5 mm closer to the tyre for improved chain clearance on the frame. The old 630 pitch sprocket is still fitted. Couldn't believe how heavy the 630 chain was compared to the 520 on my ducati.

I have also replaced the wheel bearings. I realise that I will need to do this again after powder coating, but the old bearings were seized solid, and I need to be able to roll the bike around the garage.

Based on Katmans advice, the GSX hub spacer will be reused. The bandit item on the right is slightly longer, and I undertsand this creates issues with lateral loadiing on the wheel bearings.

 

[ozgs]

I have fitted the rear wheel to the swingarm using the GSX hub and the what I assume are the the standard bandit spacers (supplied with the axle). With these fitted there is an approximately 6mm gap between the spacer and the swingarm. See pic.

If these are standard bandit spacers, I am assuming that the gap is related to the gsx hub being physically narrower than the bandit hub. I don't have the bandit hub to measure the difference. Given this I assume that I need a sprocket side spacer of around 21.5mm.

Can anyone confirm?

Thanks in advance.

 

[ozgs]

Picked up a 520 pitch 48 tooth rear sprocket and sprocket grease seal this morning. The sprocket is fitment for early 80's DR500 as well as others. I have spent a fair bit of time online trying to source this sort of stuff but have been very impressed with prices from my local dealer.

JT Sprockets equivalent part number is JTR1825.48

 

[ozgs]

Easy to see the advantages of the 520 conversion when clearance is limited. 520 sprocket is 6mm compared to the 10mm of the 630 and much lighter. A DID ERV3 520 chain is 18.6mm across the pins compared to the 24mm of the chain that was fitted.

Interesting to note the difference in diameter due to change of pitch. The 630 is a 42 tooth and is 10mm bigger in diameter than the 48 tooth 520 sprocket.

 

[Guest]

Hey mate, looks like an awesome project! Don't forget to add Ikons as a possible shock supplier, good Aussie brand

Going by that sticker for Boyd Yung M/C on the sprocket, you're in or near Toowoomba.

We're having a get together 5th Feb from Brissie up to the Ettamogah Pub if you're keen, and it's cool if the GS isn't ready...

 

[ozgs]

Hey mate, looks like an awesome project! Don't forget to add Ikons as a possible shock supplier, good Aussie brand

Going by that sticker for Boyd Yung M/C on the sprocket, you're in or near Toowoomba.

We're having a get together 5th Feb from Brissie up to the Ettamogah Pub if you're keen, and it's cool if the GS isn't ready...

Hi Pete,
Yes I am in Toowoomba. I was only doing some research on shocks last night. The Ikon shocks would be probably ideal as the spring doesn't go all the way to the bottom solving any chain clearance issues. If they are good enough for Robbie Phillis's racebike, they are good enough for me. I didn't actually realise they were an Australian brand. Do you know of anyone in Brisbane that can supply these?

The GS definitely wouldn't be ready for the 5th. Would you be happy to have a ducati along?

 

[mike-s]

You can buy them direct, the company that bought all the fabrication tools and makes them is Proven Suspension (contact page here). However it appears they are redirecting all content to their Ikon page, so you may have to contact them via the ikon page)

 

[Guest]

I shot them an email to ask where in Brissie I could buy them and they said any dealer can resell them, but they also sell direct.

For $630 I got my fork springs and shocks delivered to my PO Box direct from them, and yeah Mike's right, Proven Suspension is the mob that do them now, but they're basically the original Koni's rebranded I believe.

I've got just over 700km's on my 450 since the rebuild and so far I'm loving the Ikons, a world of difference to the stockers that were on there.

You're more than welcome to join us on the Ducati for sure! The more the merrier right?

Here's the link to the ride details thread:

http://www.thegsresources.com/_forum/showthread.php?t=185926

And I actually own a Ducati myself, although it's not currently rideable and I'm sure has a little less displacement than whatever you'll be riding...