Oz GS1000 resto and GSX1100 cafe builds

[blackhammer]

I also really wish I could change the title of this thread... All my plans have changed so much since starting out.

thread should just be: gsx cafe build and dreams of a gs1000 Resto

you just don't realise these things take so damm long to finish!

 

[Guest]

Good work!! I'm so envious of your space. I can only 100% agree with you there too, I was hoping my Kat would be done by early next year but I really can't see it being done in the next year even the way things are going...

What did you use for a fan for your extraction? I've been thinking of how to finalise my shed build by setting it up for spraying and have been thinking of fans... my paranoia says explosion proof but the price is insane for hobby use...

 

[blackhammer]

Sorry Pete, only just saw your reply. You know i never considered the potential for igniting fumes using a household fan
But nothing happened....so in my case it seems ignorance is bliss..

some update pics, exhaust is taking a little longer than i though. but most other things are completed.
just need brake lines, dual throttle cables, new clutch cable and mount the hall sensor for the speedo.
i sanblasted, cleaned painted and rebuilt all the calipers.
got a good deal on Ti bolts (read free) so using them in the calipers, discs and will use on header mounts.
I also picked up another project for when this is finished....

Header flanges, milled from solid stainless. On the far right is the template we used kindly donated by Ozman. (will get it back to you soon Steve)

all fits nicely

Immensely satisfying getting these to come together.

it doesnt look like alot of work to get the front and rear braking set up, but i believe overall it has consumed the most of my time

so very close to a ride. but i want to make sure ive covered everything before it hits the streets.

new project for after the GS is finished, any guesses to what it is???

So i guess only small stuff to go now, so prob no more updates until the bikes finished.
Ive bought a block of land and will start building a new home in Feb, so no more bike building fun from Feb onward i would think.
So this project has to be finished by then, i think it should.
hope everyone's builds are going well.

Nate.

 

[Chuck78]

79 rm250?

I've really been wanting an 80-81 PE175 (enduro/trail version of the RM125) ... or 80-81 PE400. May have a 77 PE250 falling in my lap for almost free tho...

Project is looking incredible mate... Superb job

 

[Guest]

Mate that's awesome! And your wiring in that copper tubing is working in real well too. Great job!

 

[blackhammer]

As usual chuck pretty close, 77 PE 250, hope you end up getting one too ��

Unsure what hat I'll do with it yet, have some mates that race vintage flat track and they are encouraging me to have a go and they think I could make the bike competitive, but I'm leaning towards restoration and getting it on the road with registration. Will depend on parts cost I think, as it's missing a lot of the standard parts and an initial look at eBay etc. shows things might get pricey.

thanks Pete, I'm sure u two guys are the only ones that check out my updates ��

 

[Guest]

I dunno, vintage flat track sounds fun!

Your thread's got over 10,000 views, reckon there's a few more following not commenting

 

[blackhammer]

It's a sight to behold Pete, a bunch of crazy dudes on pre 80s smokers screaming around the track... seems to be a very popular class right now.

i reckon 9000 of those views are just me checking i posted the pics ok
or maybe there a more closet cafe fans than we think

Ive taken so long on this bike I've probably missed the fad, and I'll have to get onto that gs1000 Resto to be cool ��

 

[Guest]

That sounds like fun to me Nate! Wish I had time to go watch some of that sort of stuff... haven't even got out to the Aussie Superbikes or even club events for years.

Tell you what, I'll have a slow race with you... my Kat is taking way too long as well...

 

[Weasel]

Absolutely stunning. Great work, love the color scheme and the lines.

 

[blackhammer]

the end.....kinda

the end.....kinda

So I kind of intended this to be my last post on this build thread before I went back to forum lurking, but, the bike isn't finished with me.

finished exhaust, brakes etc.
the 33mm smoothbores ended up having a few parts missing around vacuum sealing them, and the tuner I had lined up with a dyno didn't want to touch them anyway, so I bought 36mm RS's.

Fireed up straight away, everything electrical worked which was nice, no oil leaks either.

took it for a short ride and it was great, rode beautifully, no wobbles, no tracking, brakes were awesome, power was there, not that I got stuck into it or anything.
sounds really good too, I was trying to go for a yoshi type look to the pipes but got a bit Fixated on bends and following the frame, two well packed baffles in each side and it really isn't obnoxiously loud. At idle it is in fact very quiet.

Took it to the dyno and that's where all the bad news started, first run showed up major clutch slippage. Then we noticed the burning oil smell and smoking exhaust on back off.
couldnt really get a power run in because of the clutch so We took it off and I decided to ride it around for the end of summer then rebuild the top end and replace the clutch during the winter.

took it for a couple of long rides and was loving it except I've massively over geared it, revs way too high on the highway... then it quit suddenly after doing about 150km, no power. The only thing I forgot to check in my excitement to ride was if the thing was charging, seems the 1100 stator I put in either was broken or doesn't work with an 1150 flywheel, the bike just ran on the battery this whole time.
my mates 80 gsx1100 (stock bike) also quit on the same ride, starter clutch disintegrated and demolished the starter.

so the winter garage is full with broken bikes, pulling the head on my 1150 this weekend to decide how much cash I'll throw at it, not sure if I should work it up or not, a nice street bike is all I'm after really, with a reliable clutch. And need to fix old mates 1100, he's blaming me for buying and reckons his fat boy is more reliable haha, really wish 8v 1000 starter clutches would work in the 1100s...tons of those around but no 1100 stuff at my local wreckers..

anyway, couple of pics of it finished...

back to lurking untill till I have a dyno sheet to post, enjoy your summer USA, Southern Hemisphere into hibernation and wrench mode.

 

[dwilson0725]

Gorgeous. I think that exhaust is the cherry on top. Great job.

 

[steve murdoch]

The exhaust looks great.
Following the lines of the engine/frame and tucking it in so close, obviously no worries about ground clearance.

 

[Guest]

Mate she looks fantastic! I'd be 100% proud of that if I were you! And yeah, I love those pipes, they are absolutely spot on.

 

[blackhammer]

I won the slow race Pete ;-)

pipes have proved somewhat controversial amongst my friends....either love or hate...glad you guys like them

 

[Guest]

Hahaha yeah my slow race is just getting slower... I reckon those pipes will work out the true friends from the bad ones in that case... hahahaha

 

[blackhammer]

Top end rebuild, pic heavy post.

Top end rebuild, pic heavy post.

Just got the bike going again after the top end refresh.
76mm wiseco
mild port job
new hd timing chain, stock cams, manual tensioner, hd rear guide.
standard valves, new springs
Welded clutch, new standard plates and springs

Just crusing around, feels good, sounds different from stock.
rs36 jetting still as it came out of the box, no doubt will have to look into that, no idea what I'll need with my pipes...

anyway, it's running well, and I'm just pleased I got it all back together with no leaks and it running.

some pics for any followers. Next post with a dyno sheet hopefully.

crank and gearbox looking ok.

First engine I've ever rebuilt, exciting getting the new bits.

Used suzuki gaskets, clutch plates and springs. No leaks.

Rebuilt and welded as pretty much everyone says to. Re shimmed as well.

I sent the head away for the porting

Back in the bike and on the road. Great riding weather. Think I'm going to need a cooler though, oil temps sit pretty consistently at 220F.

 

[blackhammer]

Im really happy with the bike, rides beautifully, perhaps a little loud now, will start thinking about proper muffler ideas instead of just baffles, also an oil cooler is on the cards.
sprokets still need to be changed, revs are up way too high at highway speeds.
will be really happy if I can get 120 hp at the wheel with this motor, hopefully not being unrealistic.

very cathartic posting to this build thread, hope some of you find it interesting, even if cafe isn't your thing.

cheers all, happy new year and have a great 2018
Nate.

 

[steve murdoch]

Like the look, Nate.
I would think the mufflers should get sorted before the dyno run for jetting.
Also jealous you are in summer mode.

 

[Guest]

Fantastic Nate! Yes, new bits are always exciting, and getting back on it and enjoying your own handiwork is one of the most satisfactory feelings ever in my opinion. Good choice on sticking with genuine gaskets too!

I still say those pipes look awesome

If you reckon they're too loud definitely do something though, I had to wear earplugs when I first put the velocity stacks on the 450 as the noise at 5K RPM and up for any length of time was just too loud and was borderline giving me a headache, some foam filter material sorted that out.

I was given a tip to wrap exhaust baffles in steel wool (the kind you get from the supermarket to scrub the dishes with) rather than the fibreglass packing as the fibreglass just disappears way too quick whereas the steel wool lasts a while. Never tried it myself though...

As a side note... what are you planning to do with the 33mm smoothbores with the missing parts?