Suzuki GS1100G project

[manxmann]

Thanks for your kind offer JimmyR, but I have a set of recoverable 4:1 headers. It's my OEM pipes that are badly rusted.

Where are you ordering your genuine parts from ? I have found Mic Hone Suzuki really know their stuff ( Mick Hone Motorcycles )

Thanks again
Cheers

[JimmyR]

I get my OEM parts from various sources - I was using Ebay a fair bit but now I am using McCulloch's Suzuki in Vic Park because for a lot of the parts they can get them in overnight. I have been pleasantly surprised at just how reliable they are. Very friendly bunch in there - quite different from a lot of the dealers I have dealt with before where they want to sell you a bike and that's it. If they can be arsed ordering parts it's actually worth while for them because the margin on parts is higher than on bikes.

I really hope my generator gasket turns up today!

[manxmann]

I took my rusty headers to the platers today for an expert opinion & came away pleasantly suprised. He reckons they'll come up looking good, maybe not 100% - but good. So I am going to get the cancer eaten sections repaired which should be bugger-all to someone with an oxy set, then off to the chromers they go.

I checked with Maddington Wreckers, but Mark doesn't have originals at the moment.

Haven't been back to the Powder Coaters yet to see if my rims are finished, maybe leave it till Friday now. As I say "plenty other work to do !" ( and that doesn't include domestic chores .... .....)

[JimmyR]

Pleased to hear you can salvage your pipes. That must be a relief!

Well I got a fair bit done today. Finished hooking up the clutch - had to chase out some powder coat of the thread on the lever but now it looks like I have a brand new one. Gavin the mobile bike dude came around and helped me get the stubborn rotor off my crank shaft so I can install the Dyna ignition. He's good bloke! Gave me heaps of good advice on the project.

And I finished installing the new stator and now the generator cover is back on and looking great - I cleaned it up while it was off the bike. After all that I spent some time shoving wires down PVC tubing to protect it as it goes from under the saddle to the headlight. So tomorrow I hope I can get time to wire up loads of connections inside the headlight. I bought a good quality wire stripper and a heavy duty crimper so I'm all set to assemble all my plugs! Quite looking forward to doing all the wiring and I think that says something a bit strange about me...

[JimmyR]

Spent all yesterday sorting the exhaust. Bloody hard work - the hardest thing I've had to do yet. It took a LOT of persuasion over the day and it was a very humid day so I had the sweat pouring off me in buckets. But I think it has been worth it. The exhaust looks exactly how I wanted in terms of lines and how well it tucks away under the frame. I love the little reverse cones on the mufflers. It means I have to work out another way to mount a side stand as now the stock stand won't fit, but I'll get that sorted I'm sure.

exhaust001 copy.jpg

exhaust002 copy.jpg

And here is where I have an issue with the side stand.

exhaust004 copy.jpg

[JimmyR]

BTW I had to remove quite a bit of metal from the rear exhaust mounting brackets so that the mufflers didn't hit the rear axle. I wore out two cutting discs on my grinder. You can just see a rebate on the inside of the bracket in the first pic above. Had to drill a new hole in the bracket too, but that's ok because I may cut the end of the brackets anyway and they will get the texture black powder coat eventually.

Depending on how the bike turns out I may wrap the headers too. I think it would suit the bike. I am liking the fatter front tyre and have placed the new seat on the bike for the pic so I can visualise the product.

[manxmann]

Picked my rims & rear footrest mounts up from the powder coaters a couple of days ago. After waiting since around Christmas & having been promised faithfully the bits would be done and giving them an extra week after their latest "guaranteed" completion date. I called there, full of expectation to see my once nicely polished bits sitting where they had been for the last month - now covered in crap !

I brought the bits home in disgust. I am fed up with listening to their bullshit. If it's going to take X amount of time to do the job, or they are not really that keen on doing it. What's wrong with telling a man to start with ? I can handle that. But I hate being jerked around.

So now it's back to about Dec 27th & re think the situation. Bugger.

I may just paint the rims & stick some "Rim Halos" on them. Not original I know, but could look OK.

I dropped the exhausts off for repair today ............................ ?????

[JimmyR]

Incredibly frustrating isn't it? It's difficult at the powdercoaters I use because they are such nice blokes and are very interested in bikes. At least my stuff got done eventually, and it looks fantastic. I will go there again but will warn them again about my wife who has a second dan black belt in Muay Thai kickboxing...

The last few days have been frustrating too. I have nearly finished the wiring but all sorts of problems arise. I got the battery box from the aluminium guys and installed it but somehow the battery is taller than it was when I first measured it! So I have had to cut away some of my underseat tray which means relocating the indicator relay and the starter motor relay. I put the regulator/rectifier underneath the tray. I wish motorbikes didn't need all this stuff!

[XS650]

Hi Jimmy quick question - who did your battery box? i've asked a couple of aly fabrication places but none were that keen..

[JimmyR]

Custom aluminium 74 Collingwood st Osborne Park. I found 'em online and just walked in there with a cardboard version of what I wanted with all the dimensions written on it. I was going to take plans but I'd already made a cardboard mockup to test fit so took that instead. They are very helpful in there!

[JimmyR]

FWIW here is said battery box. This is without the cover section I had made as well:

bike005 copy.jpg

[JimmyR]

And here are my newly made indicator mounts. Sure, other people can make fuel tanks and entire engines from matchsticks but this is me! These will be powdercoated texture black and the wiring sealed with black heatshrink.

indicators001 copy.jpg

indicators005 copy.jpg

[CrotchRocket]

I get my OEM parts from various sources - I was using Ebay a fair bit but now I am using McCulloch's Suzuki in Vic Park because for a lot of the parts they can get them in overnight. I have been pleasantly surprised at just how reliable they are. Very friendly bunch in there - quite different from a lot of the dealers I have dealt with before where they want to sell you a bike and that's it. If they can be arsed ordering parts it's actually worth while for them because the margin on parts is higher than on bikes.

I really hope my generator gasket turns up today!

+1 for McCulloch's
one of the main reasons i regret selling my suzuki. wish all bike shops were like them

"yeah we will have to get that part from sydney"
"ah crap how long will that take?"
"it will be here by tomorrow lunchtime"

the bloke told no lies.

great build btw, keep up the good work mate.

[JimmyR]

Yep I was in McCulloch's again yesterday. I am really impressed with how helpful they are. The only other bike place that comes close is American Motorcycles down the road - the parts guys there are very cool too. But the Kawasaki place where I bought my first two bikes in Ossy Park sucked.

Anyway today I got my electrics all working - yay! I have completely rewired the bike from scratch and was almost surprised that it worked. I did have a few little issues to sort out but considering that I have non-stock clocks, switchgear and an all-new charging and ignition system I think it has all gone swimmingly. And I got to see how the LED backlighting on the clocks looks - fantastic! They glow white.

So this week I will get some help to get the bike running again. I'm not good at engines. I can replace bits but when it gets to shimming valves and synching carbs I want help to make sure it all goes right Then it's time to get it registered. Exciting times!

[manxmann]

Tape up & Paint Wheel Rims Feb 2012 email (12).jpg
The rims.

Sundries ready for blasting.JPG
The next little projects.

Tail lamp fitted copy Feb 2012.jpg
Slowly, slowly !

Dunno what's been going on, but I haven't been getting the normal notification of new posts for this thread. I thought everyone must have gone to ground.

Done the wiring eh JimmyR ? That musta been a real buzz............. how satisfying when things work !?

I have been busy on the previously mentioned & un-powder coated rims. I have cleaned, re-polished, painted & laquered them. I think they look OK - just hope the laquer is better than the heat proof stuff I tried on the final drive housing & fork legs.

And folks say to me "Now that you are retired, aren't you bored ? What do you do all day ?" Bloody hell, I haven't got time to scratch.

[JimmyR]

Well I took off the rear wheel today. Spent a fair bit of time with the wire wheel going over the alloy rear hub and cleaning up all the rust on the disc bolts. Cleaned up the wheel a bit and maybe tomorrow I can repaint the black bits. The tyre actually looks ok and not too old. I was pleasantly surprised that it was quite easy to remove the back wheel. I think being a shafty actually makes it easier. When I took off the hub with the drive bits in it (please excuse my overly technical use of jargon) I was amazed at how heavy it was. And pleased that all the internals look to be in excellent nick.

I also did a bit of tidying up of the wiring and bits and pieces. Tomorrow I'm hoping to pick up the rear brake calipers and indicator mounts from powdercoating and put bits back together. Still have to clean up the brake pistons but that shouldn't take long. This bike might be ridable soon... Then the real work can begin!

[JimmyR]

Well I took off the rear wheel today. Spent a fair bit of time with the wire wheel going over the alloy rear hub and cleaning up all the rust on the disc bolts. Cleaned up the wheel a bit and maybe tomorrow I can repaint the black bits. The tyre actually looks ok and not too old. I was pleasantly surprised that it was quite easy to remove the back wheel. I think being a shafty actually makes it easier. When I took off the hub with the drive bits in it (please excuse my overly technical use of jargon) I was amazed at how heavy it was. And pleased that all the internals look to be in excellent nick.

I also did a bit of tidying up of the wiring and bits and pieces. Tomorrow I'm hoping to pick up the rear brake calipers and indicator mounts from powdercoating and put bits back together. Still have to clean up the brake pistons but that shouldn't take long. This bike might be ridable soon... Then the real work can begin!

[51 New West]

FWIW here is said battery box. This is without the cover section I had made as well:

bike005 copy.jpg

Can anyone else NOT see the photo?

[JimmyR]

Comes up on my computer. This is it:

bike005 copy.jpg

[51 New West]

Got it, the battery box, very neat. And the indicator mounts? Sorry to bug you, I've been lurking in this thread for a few weeks, would hate to miss the good bits now