GSX1150 Rebuild

[ensure]

I have taken a little more width off the caliper bracket so i can get the wheel across another 2mm to the right

[/URL][/IMG]

It has made a minute difference to the alignment so I am going to leave it there.

[/URL][/IMG]

One other area that need modification was the chainguard. I have had to take a hunk out of that to give clearance to tyre

[/URL][/IMG]

This will probably prove a bit generous now as the wheel as gone back to the right a little.

 

[Rob S.]

The mechanic I use is a suspension expert with many years on the Superbike circuit with factory rides he told of me of home mechanics who got the geometry all wrong and and end up in the ER or morgue. He emphasized that even small changes can have huge effects on handling.

This is why I insisted on a 'neutral' Sportster. I also dislike the very look of most of the stock Harleys. Big fat tires or skinny ones. Undersize wheels or oversize. Not for me.

 

[wyly]

In response to an earlier question from Wyly What is the difference in weight between 2 wheels ? I have an answer

18" c/w disc and sprocket 18.7 kg
17" c/w disc and sprocket 16.6 kg

Something else I noticed with losing 13mm of ground clearance is that it is noticeably harder getting the bike up onto centrestand.
I have placed a sheet of timber on floor that i push bikes rear wheel onto before lifting onto centrestand. It makes a real difference.

[/URL][/IMG]

The side stand really needs shortening by a cm as well as the bike doesnt lean over very far. I am worried it will fall to the right if i am not careful.

Good to know thanks! So for two wheels about an 4kg/8lb weight savings in dry wt, as it's a rolling unsprung weight it'll improve suspension/handling.

It was never easy to get it up on the centre stand but as my Hindle headers required removal the centre stand it's not a issue. I agree the side stand was a bit long, on the first day riding after I restored the efe to oem the sidestand folded up and it fell on to the curb damaging the new paint, not a happy day.

Have you converted the front wheel to a 17" from the oem 16" ?

 

[ensure]

Wyly

Yes I have changed front wheel as well. Check out Post #41

[/URL][/IMG]

Once I get the front forks off again to replace the seals I will post the weight comparison for the front end as well

Getting onto the final tasks now I have had to come up with a method to light the numberplate seeing as I have removed the stock option. In reality I wll probably never ride the bike at night but if i want to get it registered for the road then it is a neccesity.

Due to positioning of numberplate I thought that I could use the illumination from rear tail lamps to illuminate plate if i cut some holes in bottom of plastic lense

[/URL][/IMG]

So I drilled a bunch of holes across the bottom face

[/URL][/IMG]

Because of the angle of the face and thickness of plastic I worked out there would not be any spill light to shine in the eyes of following motorists

[/URL][/IMG]

Unfortunately it does not give enough illumination so an additional light source is required

[/URL][/IMG]

Need to get a LED striplight in there.

 

[wyly]

I purchased a led set up from the US, it didn't cost much and it blends in perfectly, if you're interested I can search through my invoices to see where I found it.

 

[wyly]

So even with the 17" front the sidestand was still too short?

 

[wyly]

This is why I insisted on a 'neutral' Sportster. I also dislike the very look of most of the stock Harleys. Big fat tires or skinny ones. Undersize wheels or oversize. Not for me.

Yeah there's a bit of vanity with tires bigger looking better but going bigger can definitely come with detrimental consequences to handling, factory engineers of the day made careful calculations based on the bikes geometry and tire technology. The efe design did allow for an optional larger factory wheel tire combo I don't recall exactly how much larger but I think it was .5".

 

[Rob S.]

The efe design did allow for an optional larger factory wheel tire combo I don't recall exactly how much larger but I think it was .5".

Very interesting! Can anyone add to that?

 

[dorkburger]

As far as I know, the 84 model had a 3? wide rear wheel like the earlier 1100e bikes. 85 on had 3.5.

 

[wyly]

Yes it could be because of the year, I nearly bought the larger wheel on this site. Manufacturers also have different specs dependent on the country or region that the bike is sold, I don't know if that applies here. I've noticed Canadian bikes are frequently different from US or European versions.

 

[ensure]

I have noted previously the old wheel size. I made the mistake of putting it in big letters

[/URL][/IMG]


My main reason for swapping it over were
1. Get a better range of modern tyres to use
2. I was getting near the end of project so needed something else to fiddle with
3. Learn something new. Once you have removed and re-installed a wheel 20 times it becomes easy

I could have put a 150/60-17 tyre on but there were only new ones available and that was going to cost an additional $120 over a slightly used 160/60-17 so the wider tyre won. To be fair I hadn't even thought about chain clearance at that point.

Anyway I have moved the rear wheel over to the right far enough now that I can put the wider Cush drive from the original GSXR-750 wheel back on and remove the spacers. Chain clearance is now a massive 6mm or so.

Another test ride and the bike really does feel different now. Going through corners it tips into them just like I was riding on my 2010 GSXR-1000. And that is why you want to swap out the old forks and wheels for new (relatively) ones. My 3rd loop of my test course (about 15km) and i am starting to scrape my toes on some corners, not intentionally, I just have more confidence when leaning in.
And I still have the original rear shock in so that is probably causing some issues. The problem is new ones cost $799 locally.

 

[dorkburger]

I have a Ducati M900 shock in place of the original. Nearly a bolt in except that I had to mount it upside down and it was recommended to use the GS spring which I did. It was a whopping $60 used.

 

[wyly]

I'd like to go to larger rubber in the future the 16" front doesn't leave many options for tire selection.

I don't think I'd need to go to as large 160 on the rear but Ensure is demonstrating it can be done.

 

[ensure]

For the Number plate light I have bought a 10cm long LED striplight with connector

[/URL][/IMG]

and found an old piece of plastic tube to mount it in

[/URL][/IMG]

I then glued it over the holes I had drilled in Lens, double checking I had the LEDs pointing in the correct direction

[/URL][/IMG]


Drill a hole to get the wires out

[/URL][/IMG]

A quick bench test

[/URL][/IMG]


Now to get it back on the bike

 

[wyly]

That worked out nicely. When I modified my tail assembly I wondered why didn't Suzuki do exactly what you have done, it seemed the easy solution rather than the complex monstrosity they produced.

 

[wyly]

Yeah but 35 years ago it was the "thing". If you look at an 84 Corvette or Dodge Daytona they match the styling of these bikes pretty much.

the part in question wasn't styling feature, it was a clumsy attempt to cast light on the plate to meet road legal requirements it was finished in flat black in order to obscure it. My 79 CBX has exactly the same set up as what ensure has manufactured here.

 

[ensure]

I thought I would try and measure bikes weight to see what sort of difference I have made. I pushed bike up onto some 6x1 timber and thought if I put some scales front and rear I could measure it in 2 halves fairly accurately by just pushing the bike back & forth a bit.

Front End first

[/URL][/IMG]


138kg. Unfortunately the limit on scales (in small print) was 130kg on scales and now I just get Error message so this is yet to be finalised.

here is updated drawing of wheel installation with new Cush Drive and different spacers for anyone who might want to replicate this method

[/URL][/IMG]

 

[wyly]

Start with factory dry weight 524 lbs and deduct weight of any part removed , add back whatever after market you replace it with.
Oem exhaust weighs a hefty 34 lbs if you don't have them to weigh.
I haven't done a calculation lately for my efe but I believe it's about 480 lbs/ 218kg

 

[Rob S.]

I weighed my 11E once by separately weighing the front and back with a bathroom scale. Seems like it works because the total was very close to the weight Cycle World listed in 1982.

 

[ensure]

So I bought some new bathroom scales (180kg max) and tried again, I got the following readings

Front - 120kg
Rear - 118kg

Total 238kg

Bear in mind that this is wet weight, I have about 14 litres of petrol and 3.5 litres of oil in there so if we subtract that at 1kg/litre I get about 220kg

Dry Weight from manual for a ES is 237kg so I think I am pretty close to accurate based on what I have removed