TCK's GS1100ESD Gixxer/Bandit mod thread...

[Billy Ricks]

2 other options here ....

pin & weld 2 stock sprockets together with the teeth removed from the rear one & the centre of the front one dished or cut out completely gives you around 9mm of ofsett you can then space it out as normal or....

for a couple more mm on the spacing you can machine the back of the nut down this allows you to still get the locking part onto the thread

I already have a custom sprocket in the works. I was going to go the welded route years ago using two sprockets but never got around to it. Chain alignment is already decent as it is, just trying to do a little better. I'm running a 16 tooth sprocket right now and wanted to go up a tooth anyway.

 

[jwhelan65]

Runner

Runner

I have the runner, this was a dry run to fit everything

 

[TheCafeKid]

I have the runner, this was a dry run to fit everything

J you have a PM sir...


TCK

 

[tone]

I have the runner, this was a dry run to fit everything

understood i wish i hadnt mentioned it now

 

[TheCafeKid]

do you have a chain runner on there as from the pic it looks like you have an issue with the chain chewing into the arm

Dumb question perhaps, but keep in mind modern equipment is somewhat foreign to me still. What is a chain runner? Im guessing its a guide to keep the chain up off the swinger? But what is IT made out of to prevent IT from chewing up the chain, or being chewed up itself?

 

[Guest]

The chain "runner" prevents the chain from doing the chewing on the top of the swingarm. On my bike I used the one that came with the bandit swingarm. Its not a perfect fit. You have to hog out some of the rubber along the sides of the swingarm to make it fit.

Katman suggested that some folks were taking just a pad (like 1.5" X 3") of hard plastic (maybe cut down from a modern chain runner) and adhering that to the top of the swingarm where contact is likely to occur. A double sided tape like 3M's VHB tape would do a good job of sticking it in place.

The material used on my FZ1 is a very hard plastic that would be ideal. The material on the bandit chain runner is a softer rubber that will eventually wear through although after 7000 miles its still doing what its suppose to. Also note that if you use the bandit one it wont be perfectly aligned ie the chain won't be centered on the pad. The main thing is just to keep the chain off the swingarm. Its not really in a place that is easily visible.

 

[TheCafeKid]

The chain "runner" prevents the chain from doing the chewing on the top of the swingarm. On my bike I used the one that came with the bandit swingarm. Its not a perfect fit. You have to hog out some of the rubber along the sides of the swingarm to make it fit.

Katman suggested that some folks were taking just a pad (like 1.5" X 3") of hard plastic (maybe cut down from a modern chain runner) and adhering that to the top of the swingarm where contact is likely to occur. A double sided tape like 3M's VHB tape would do a good job of sticking it in place.

The material used on my FZ1 is a very hard plastic that would be ideal. The material on the bandit chain runner is a softer rubber that will eventually wear through although after 7000 miles its still doing what its suppose to. Also note that if you use the bandit one it wont be perfectly aligned ie the chain won't be centered on the pad. The main thing is just to keep the chain off the swingarm. Its not really in a place that is easily visible.

Gotcha, kinda figured thats what it was, but aside from plastic i couldnt think of what they could use. I guess rubber works! Although, when they DO wear out, are they replaceable? I would hope so.

 

[salty_monk]

Ones I've seen appeared to be made from Nylon.

Dan

 

[jwhelan65]

Stock runner

Stock runner

Here is a stock 98 Bandit chain runner for reference

 

[TheCafeKid]

Gotcha. Like I said, ive never been interested enough in the modern bikes to look closely enough to see one of those. Makes complete sense tho. You can only make the swinger so wide and keep the countersprocket so small that eventually you will have some interference problems. I have seen bikes that actually run somewhat of a carrier bearing type cog set up...its odd.

Anyway, thanks for the info fellas. I plan on using a 520 chain with a 13mm offset sprocket, so hopefully i dont have to do ANY grinding, if only very little, to any of the frame. I am trying to avoid that at ALL COSTS. Im excited about this project. Like I said, the ES is only a test bed for the suspension mods, i hope to be able to score a basket case 1100EZ/ED at some point, so long as the frame is titleable, it has a wiring harness and gauges, and the bodywork looks ok, i could care less about the motor or anything else. I'll put these parts and then my "stupid retarded expensively fast" motor in it...lol

 

[Guest]

TCK

Sure you can replace them but I doubt its something most bikers will have do in their life times.


In an email we spoke about how to get the stock GS rear brake to work with the Bandit swingarm. When I first started adapting the Bandit swingarm that was the direction I was heading. When you get yours and you do a dry fit your going to see that its tight in there.

If you can find it any more Katman had a thread on how he did it on his Katana

The problem I had was the shaft from the rear master cylinder was coming down through the swingarm in a place that was too tight.

If you look at the item on the end of the brake shaft arm in the two photos what you should see if it was stock is two arms that project straight up from the collar. You'll see that I had my machinist friend put an "L" into the arm (lower pic) that the master cylinder shaft hooks to. This effectively moved the location over to where it would work. The other arm is unmodified and is for the return spring. This won't make any sense to you till you stare at your dry fit for about four days then you'll say OK now I get it.

I had everything hooked up and operating in my garage but never took it on the road. I eventually went to the ZX12R set up which looks and operates much better on my bike.

I like the stock foot pegs on the 83 better than my stock 82 and would have stayed with this set up if I could have gotten the 83 pegs to fit but they don't interchange. The fact that the 82 and 83 peg mounting plates are different may mean that what I'm showing you above may not be a perfect fit on your set up.

Sorry that's all I've got for photos of this piece. I don't have anything of it installed it was too tight to get a picture of. Hope this helps.

If you need to borrow my piece you can have for a while but I'll need it back. Shoot me an email if you do. What I can't remeber was if I moved the master cylinder location at all, don't think I did but its possible.

By the way I know I suggested you hook up with Jwhelan65 however, if your bike is an 83 then the mounting hole locations on the ZX12R mounting plates might be slightly different (enough so that it probably won't work)

 

[jwhelan65]

520 Bandit rear conversion

520 Bandit rear conversion

Here is look at your spacing using a 520 conversion with a 180 Bandit rear swingarm. Spacers, provided by Katman...520 solves a lot of issues most importantly keeping the chain off the shocks.

 

[TheCafeKid]

TCK

Sure you can replace them but I doubt its something most bikers will have do in their life times.


In an email we spoke about how to get the stock GS rear brake to work with the Bandit swingarm. When I first started adapting the Bandit swingarm that was the direction I was heading. When you get yours and you do a dry fit your going to see that its tight in there.

If you can find it any more Katman had a thread on how he did it on his Katana

The problem I had was the shaft from the rear master cylinder was coming down through the swingarm in a place that was too tight.

If you look at the item on the end of the brake shaft arm in the two photos what you should see if it was stock is two arms that project straight up from the collar. You'll see that I had my machinist friend put an "L" into the arm (lower pic) that the master cylinder shaft hooks to. This effectively moved the location over to where it would work. The other arm is unmodified and is for the return spring. This won't make any sense to you till you stare at your dry fit for about four days then you'll say OK now I get it.

I had everything hooked up and operating in my garage but never took it on the road. I eventually went to the ZX12R set up which looks and operates much better on my bike.

I like the stock foot pegs on the 83 better than my stock 82 and would have stayed with this set up if I could have gotten the 83 pegs to fit but they don't interchange. The fact that the 82 and 83 peg mounting plates are different may mean that what I'm showing you above may not be a perfect fit on your set up.

Sorry that's all I've got for photos of this piece. I don't have anything of it installed it was too tight to get a picture of. Hope this helps.

If you need to borrow my piece you can have for a while but I'll need it back. Shoot me an email if you do. What I can't remeber was if I moved the master cylinder location at all, don't think I did but its possible.

By the way I know I suggested you hook up with Jwhelan65 however, if your bike is an 83 then the mounting hole locations on the ZX12R mounting plates might be slightly different (enough so that it probably won't work)

Isle,

yeah i realized that just today actually when looking again at his bike. They are just different enough to be a PITA. I had forgotten his was an 82, so J, those plates arent going to work with my set up. Isle if you dont mind lending me your modified piece, I MAY be able to track someone down to copy it. Hell, maybe if i sent it to Rob (katman) HE might be able to do it. Unfortunately, Im in the process of tracking down a decent, TRUSTWORTHY machinist around my parts. Problem is, most of the big places wont do small one off stuff, and the ones who do are flybynighters and drunks. I could give him the stuff i need worked on, and end up never seeing it again. I have been talking to a couple of guys here on the board, and if I have to send some stuff out to them to get done, I will. It would be super cool to be able to retain the stock pegs, at least on the ES. Once I swapped it over to my "Christine" machine (thats what im gonna call her, cos this project has me possessed. I obsess about it day and night, and have realized that i dont really care how much money i end up throwing at it....in the end, the bike will probably kill me, or get me killed...LMAO) I will prolly go with rearsets, as it will be 90% corner carver at that point, and trips on it will probably be no further than WV or KY. "Two tanks to get there " type trips. I cant see riding that thing much further, but hell, who knows, it may end up just as comfy as the ES would be.

So, it will be a while before i am even ready to modify anything, but when the time comes and if you dont mind lending that to me to get a copy made up, I would appreciate it greatly.

Again, thanks to all you guys for your input and suggestions. I wouldnt be attempting this without your help and direction, as i would be too afraid of facking something up permanently....LOL

 

[TheCafeKid]

Oh...another question on that. I am pretty familiar with the set up of the stock MCs on these things, as ive taken the one off my cafe countless times in the mods that I did to it trying to get things to work out. From what I am seeing, that "L" you put in it, wouldnt you have had to move the MC, OUT, to keep the plunger in line? Seems like that would have put some sideways torque on it. But then again, its kind of a ball and socket joint on the other end of the plunger, so maybe it doesnt have to be DIRECTLY in line??

 

[jwhelan65]

Right there wit ya

Right there wit ya

I here ya on the obsession thing....my wife looks at me like.. "what kind of creature did I mary" as she hands me a UPS delivery (full of parts of course)

 

[TheCafeKid]

Here is look at your spacing using a 520 conversion with a 180 Bandit rear swingarm. Spacers, provided by Katman...520 solves a lot of issues most importantly keeping the chain off the shocks.

Another way of doing that, if one had thought about it in advance, would be to push those bottom shock mounts out perhaps another 1/8-1/4 inch and then space them out up top with an extra washer to keep the shocks in line. there is just enough room on the swinger it looks like, and You might be able to use a 530 in that case. Not that you NEED 530, as 520 is nearly as strong with todays alloys. The GS stock motor seems to me, doesnt turn enough HP to mangle a 520 chain. Now if you have some serious mods done, i might reconsider that thought, but even then, I am pretty sure i read the Busa comes with a 520, and it DEFINATELY puts out some ponies, tho not quite the constant torque thru the powerband maybe. Never actually put one thru the wringer to try it...I rode a ZX14 and a Busa around the block once, and just in first gear its enough power to make you wet yourself with giddyness. Just not my thing tho...

 

[TheCafeKid]

I here ya on the obsession thing....my wife looks at me like.. "what kind of creature did I mary" as she hands me a UPS delivery (full of parts of course)

HAHA! you should see my basement. Its FULL of empty parts boxes. I have no wifey to contend with, sometimes thats bad i guess, but for now, whilst i toil away at all these projects, i think of it as a blessing. I can get all my "toys" together ahead of time, get it out of my system for the most part, and THEN worry bout the woman. Of course, eventually, I will find another project i want to do to a bike....good thing my Volvo is ugly, i dont mind IT sitting in the weather....the garage is for BIKES! LOL

 

[Guest]

Here is look at your spacing using a 520 conversion with a 180 Bandit rear swingarm. Spacers, provided by Katman...520 solves a lot of issues most importantly keeping the chain off the shocks.

Coming along nicely. I measured the width at the widest point of the 170 BT-021 Bridgestone Radial on my GS and it measured 6.75 inches. The 180 BT-021 on my FZ1 measures 7.05 or so. I'm measuring at the wide point of tire not rim.

I'm using 530 DID chain with 3/8 offset. I think Katman has demonstrated that with my set up that the front and rear sprockets aren't perfectly aligned however, after 7000 miles everything is wearing perfectly and it isn't an issue for me. Joe are you going to go with a Bandit chain guard or just leave it off?

I know your just dry fitting now but depending on what you go with for an exhaust you may want the rear axle to go through from the other side so the axle nut is more accessable near your rear sprocket.

 

[jwhelan65]

Yeah I have been side tracked with my business the last couple of weeks and waiting on parts (always). That is a 180 BT-020R in the pic, it measures 7.05 also. I went with 520 and a 5/8 offset in front. Not sure on the chain guard yet, I was considering cutting one up (have two) similar to yours...at least thats the plan, if not I'll run without.

As Far as the exhaust I had the V&H that was on it re-done, the style that I have is well short of the bolt so I should be ok.

Hope all is well
BACK IN THE GARAGE..

Joe

 

[TheCafeKid]

Joe between yours and Isleomans, and Kichigais, thats what made me decide to go all out on this. I have seen Isle's a few times, wasnt sure it would turn out as good on an ES with the body work...but then i kept looking at that fat rear tire on your Sig picture there. And then looked at Kichii's and Isle's again and after finding that info on using OLDER gixxer stuff just wasnt complete enough for me, I said screw it, Im doin it. It just looks BAD ASS. I hope mine turns out as well. The EZ/ED/ESDs just seem to take those modern parts so well. It looks STOCK. Not out of place at all. I love it...