GSX1100 build

[Ed74mnd]

hi guys,

thought id start a thread here following my GSX1100 build.

got bored last night so brought the old girl inside and ripped off her front.. heh

a GSXR1100 (95) front slid straight in.

already looking less frumpy, will lose some ground clearance... oh well.

poor pics as I coudnt stand on the bonnet of the car to take pics.

you can see how the salt air has turned my shiny covers in to crap.. will try some POR15 glisten PC over them next time round. any body had good results using 2 pack clear over shiny stuff?

Cheers

Ed

before
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/f97f1563.jpg

after
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/dd421734.jpg

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/e8fa54f0.jpg

[devo]

http://www.streetfighters.com.au/forum/upload/21359553396477.JPG
If ya want to spend some money on your ground clearance
problem Tarrozi rear sets are available from my good mate
and sponsor in Brissy.
These rearsets are made to bolt straight on to your model
I used to race a GS750 using the same rearsets and they aren't
that expensive.
His link is www.motorcycle-parts.com.au his name is Paul
top bloke there you will find his phone # tell him Devo sent you.

[Ed74mnd]

Hey Devo,

nice GS... good timing, i had been thinking of rear sets and was going to put on GSXR jobbies, yours look nice, and if available in Australia that give another option too.

I had some RGV ones but they just dont look right..

Cheers

Ed

[gibbo]

G'day Ed, front end is looking good mate, 2K clear over ally is no good, but POR15 glisten works a treat, make sure you follow instructions and use the AP120 ( I think) & their cleaning products. I painted some polished rims for a harley a while back it hung on no probs.

[Ed74mnd]

Thanks Gibbo, will try the Glisten in that case.

started to put the rear wheel on last nite, just need to get the axle spacers turned down.

anybody know a good ally welder in Sydney (east side?) I need to weld a torque arm mount to the underside of the swinger.

Cheers

Ed

[Large]

Hi Ed,

Looking good...That looks a lot like the front end I was going to buy off you a while back :)

Oh and welcome to ASF

[Ed74mnd]

Hey Large,

thanks for the wecome, is a cool site here. especially because it's Oz based.

these are indeed those parts, I decided to throw them all on the bike instead.

Will see how I go, this is my first go at modifying bikes, i've just completed a V8 conversion into old Holden (FE) so this is a fair bit easier to manage to get a streetable result.

hope you dont mind me hanging around, will post progress as it happens.

Cheers

Ed

[Gix11]

Yea, welcome aboard Ed.

Air-cooled suzuki's, they still look damnmed good



and welcome Ed

[devo]

Mate can't wait to see the bike finished always loved
the old Suzis.;)

[Ed74mnd]

Hey thanks guys,

have squirrelled away the parts so it's pretty easy from here I think.. just got to keep from being tempted to do more.

have got an 1133 kit for the motor with 38mm slingshot carbs, just got to figure out where to start with the jetting (what a pain).

cheers

Ed

[Ed74mnd]

rear wheel.

1995 GSXR750 - 1100 wheel.
GSXR1100 K caliper hanger.
Hayabusa caliper and torque arm.
GSX1100 sprocket carrier.
GSX beaarings, GSXR middle spacer.

sprocket side spacer machined down 15mm.
RH spacer machined down 2mm.

offset sprocket from AFAM Japan.
so far so good, the sprockets look to line up using ruler. Yet to put the 530 sprocket on the rear ( have not yet ordered it). Just leaves me to get a tag welded on for the torque arm mount.

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/26bbef97.jpg

the caliper had to be spaced as well (on the caliper mount to caliiper bolts)using a couple of washers to centre it over the rotor.

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/f98db396.jpg

Some nice 38mm CV slingshot carbs.. they fit over the std boots however some are cracked. where to get some new ones??
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/f43d73fd.jpg


If you look real close you may be able to see the SRAD speedo sender i put on the crank end.
just tack welded a bolt to the end of the crank, then put a threaded insert thru the sender mech. about .5mm out of centre but seems not too bad. hardest bit will be to mount the pick up. I will make a bracket which mounts to the cover bolts. the sprocket cover will sit over this and torque down to hold it in place.



Cheers

Ed

[Gix11]

Farkin' 'ell Ed, now your cooking mate! Nice work.

[BillyWhizz888]

Lookin sweet Ed
can't wait to see roll out shoot

[Ed74mnd]

cant wait either.

reached a stagnant spot.

got to order a rear wheel GSXR bearing spacer and new intake boots.
havent had time to head into Action.
also need to get some wiring plugs.. some bodgey previous owner had decided to solder them on with about 5mm off the plug and leave them to the weather.

i may do easy stuff like mount the (EFE) oil cooler and filter cover in the meantime.

anybody going to Motorex at Homebush this weekend?

my car is in the classic and performance pavillion. there may be some nice bikes there too, hopefully not only those Harley things.

Cheers

Ed

[Ed74mnd]

finally got my wheels on and tyres. managed to squeeze a 180 on the rear with not too many dramas.

final spacer measurements were 12mm off sprocket side, 5 mm off rotor side on rear wheel.

12mm offset (from std) sprocket and 530 chain.

currently wiring up the SRAD dash,

need a GSXR600 late 90's fuel level sender (in tank). Preferably a smashed up tank so i can get the metal to weld in. similarly wouldnt mind a early 90s GSXR1100/750 tank smashed up so i can steal the fuel filler metal section (already have the lid etc).

pics to follow tomorrow.

Cheers

Ed

[fimpBIKES]

do u need a fuel level sender that badly?

[Ed74mnd]

nope.. it's just a whim in case somebody has a tank lying about..

i ride.. i put petrol in.. i ride some more.

the tank mods will happen as i can get the needed parts i spose.

Cheers

Ed

[Ed74mnd]

finally some pics...

got a 180 on the rear now. still looks annorexic under the enormous girth of the GSX.

i should get rid of that gear sack contraption I spose... dont those blinkers look fugly?!

may hack off the black plastic guard too to clean it up.

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/DSCF0008.jpg

530 chain gang sprocket on a GSX sprocket carrier. the chain just clears the tyre, shock and frame.
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/DSCF0009.jpg

Busa caliper and hanger fits well, just need a tag welded for the torque arm. i threw on an old Yoshi after the original can fell off on Harris Street.. right in front of the coppers.. oops. the can will be re-fit under the pillion pegs and will make a shorty can out of it.

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/DSCF0010.jpg

I had a GSXR600 dash on the bike but after wiring found the LED's are stuffed.. it's a shame but i reckon an Acewell jobbie will look just right in there.
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/DSCF0006.jpg

this was the speedo sender off the 600. tacked a bolt to the output shaft then put a threaded insert in the sender "disc" would have loctited it in place.. but prolly wont need to any more...

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/DSCF0014.jpg

K&N filters just came in so now im gonna get the thing going using the 38's.

Cheers

Ed

[devo]

I have a gsxr dash here no covers just the speedo and tacho for
the 750 yours for a fifty inc postage if you are interested.

[Ed74mnd]

Hey Devo,

thanks for the offer,

I've decided to lash out and get an acewell unit.

Cheers

Ed

[fimpBIKES]

looking nice

so you used the old carrier and cush drive on the new wheel?

[Ed74mnd]

Hey fimp,

yep the old carrier and cush drive fits up perfectly. I dont have a GSXR one to compare but apparently they are wider (the GSXR ones).

Cheers

Ed

[fimpBIKES]

very interesting information
thanks

[Ed74mnd]

Project update.

since last time, the rear brake torque arm has been TIG welded on (thanks EXBEN),
Acewell round gauge mounted and wired up. I ended up having to re-wire the entire front of thebike as the factory wiring was stuffed into the back of the monstrous 8 inch headlight and was way too long.
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/37aea34b.jpg
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/3bd30d70.jpg

of course this lead to another thing, and that includes re-wiring the rest of the bike to hide all the components. I'm thinking of ditching the side covers and having a clean look like the Yoshi Katana.

anybody know a good small battery that can be mounted at angles??

so.. I decided that now was an opportune time to brace the frame. armed with some info
from oldskool suzuki and a bit of common sense Ive started to brace the frame.

first up was to de-dag the centre part of the frame, attack the unwanted battery supports and brackets with a reciprocating saw, and measure up some sizes for the braces.

the braces were then cut and mocked into position.
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/2d65e3c2.jpg

further bracing is to be added to the top part of the frame.. For this I adopted a different approach than those referenced. Due to the suggested external bracing tkaing up space (and looking ugly), I decided to put a series of "K" members down the spine of the frame. While a little more work the result will be much more appealing and stronger.

shownn is the front K member, off the back of this will come another.

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/69f0ba67.jpg

I have decided not run a x brace above the large rectanglar front brace (between engine mounts) as i wish to conceal a battery there… looking at the frame I figure I get sufficient strength from triangulating the areas back up the shock mounts then forward and up to the spine. Not as strong I realize but it does allow the benefit of hiding the battery in the most forward and upper position for the clean look I am trying to achieve.

It’s not all roses though and I made a nasty discovery the subframe is bent about 5 mm at least to the left… Fark. This pic attempts to show a crease in the shock gusset. Im not sure if this had been repaired prior (if so it’s a shit job) now what?? I doubt whether it can be pulled straight as the gusset is fully welded in from factory. I am contemplating cutting the gusset out, and pulling it back into shape then re-gussetting?? ADVICE WANTED>…

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/67ff4248.jpg

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/144b7bbb.jpg
http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/a8552662.jpg

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/879c85c0.jpg

stay tuned...

Cheers

Ed

[pt]

looks tops. love to see it when it's done. where are you for it to get that salty?

[TurboKat]

Hey Ed, I've built & ridden GS & GSX Suzi's for years now & I used to brace up all my frames similar to the way you are doing now, let me save you some trouble.
Several years back I rode my Katana to the local bike shop (Mick Hone M/C) to get some bits, while I was there, the owner of the shop (Mick) goes outside & is looking at my bike, when I come back to the bike I start talking to him & I tell you, what this guy doesn't know about GSs, GSXs & Katanas isn't worth knowing, he used to run the Suzuki factory Superbike team in the days of Dowson, Campbell & Phillis & set up all the racebikes of the period.
Anyway, he sees the bracing on my frame & asks if I'd done it myself, I say yes & he asks if I think it made any difference, I tell him that I have to be honest & say the difference is barely noticeable & the bike still hinges badly when the going gets hot, to which he replies "That's because these frames are really rigid from the factory, all the flex comes from the swingarm, it's a complete waste of time bracing the frame, if you want to reduce the flexy handling, you only have to brace the swingarm & put decent shocks on"
Apparently the GSXs & Kat's that Rob Phillis used to punt around Bathurst at unbelieveable speeds & run in the old Castrol 6 hr endurance races had standard unbraced frames with either braced standard swingers or Bob Martin cro-moly jobs - Mick said even the tube steel GS 'arms were stiffer than the alloy GSX ones.
So, armed with this seemingly credible information, I set about bracing my standard (alloy) swinger (I already had Konis on it) & MAN, WHAT A DIFFERENCE !!! I could now barrel into bumpy corners that previously I'd have to back off for, almost all the flex had gone & the bike felt incredibly stable at any speed in a corner - Mick was right, it transformed the bike like I wouldn't have imagined possible.
They used to run S&W shocks back then but a set of Konis or Ikons does wonders these days.
I just thought I'd better pass on that little gem of information for your consideration, do with it what you will. It's not often I can help someone out with any of this useless info floating around in my otherwise empty head.
Loving your build by the way, keep the progress updates coming.

[Ed74mnd]

Hey PT,

thanks, the bike got so salted because I live in Malabar and had to park it outside under a bike cover for about 9 months. Now I have moved it inside the garage where I hope it wont get too bad. I'm planning to use POR15 Glisten PC on all the shiny bits to try prevent oxidation. I have the same prob with keeping the car clean ( i have a real metal car not a plastic car)


Turbokat,

Thanks for passing on those generous words of wisdom, I feel better knowing that, OK so I may reduce the bracing now (or at least make it look more unobtrusive)

so bracing an alloy swinger... how's it done?? Im keen to rid the bike of that washy feeling it gets when pushed thru a corner.

maybe a topside swingarm brace since the bottom side has a brake torque arm.

Cheers

Ed

[pt]

hey i live just down the road in coogee! small world. my cb started to look like that after about 3 weeks outside, but thankfully i managed to comandeer some garage space and its all sweet.
good to know i have a fellow fighter enthusiast nearby.

[fimpBIKES]

thanks turbo,

thats even more of a reason to get mine sorted out (with the late model rear swinger)

[Ed74mnd]

Pt,

coogee eh? I know a couple of more guys in the area who are mad keen as well.. never enough.

fimp,
the bandit swinger is pretty much a straight in swap with the width across the swingarm pivot being very close to the GSX. it is slightly longer to accomodate the monoshock... this may or may not be a problem. I reckon a TLR arm would look the goods in there but I havent looked into any measurements. I'm going to try brace up the std alloy swinger first.

Cheers

Ed

[fimpBIKES]

yeah, i love the underbracing on the TLR swinger
but i have a k4 gsxr1000, mainly cos it is red so it'll match my frame :D

[Ed74mnd]

IN the meantime while I ponder swingsarm bracing, alternative swingarms, monoshocks and other stuff like that... I decided to throw an oil cooler on.

this particular cooler was off an EFE. the mounts are just plain old 3mm steel strap with "rivnut" inserts to allow the bolts to thread in. the horns mount beneath the cooler.

if you plan to add a cooler to your GSX make sure you use the EFE filter cover.

http://img.photobucket.com/albums/v128/Ed74mnd/GSX1100/DSCF0025.jpg

ive since tidied up the wiring, I removed the stupid, "CHECK CONTROL BOX" which alerts you to bulbs blowing on the bike.

Cheers

Ed

[kYE]

Lookin good mate! I'll head over later to help with the gas axe. :)

[Ed74mnd]

yeah thanks Kye,
teh torch will come out but not to chop anything.. merely to heat and massage the frame back..

anyway.. I tried it.. didnt work.

in the meantime, made a shorty can from an ancient RS3 Yoshi and amused myself taking a pic sans seat and rear bodywork.

i actually like this look of the bike this way.
Cheers

Ed


http://img.photobucket.com/albums/v128/Ed74mnd/b04145ac.jpg

[Gix11]

Of course you like the look of it that way Ed, That's Streetfighter stylee.......

[pt]

verrrrrrrry nice!

[Ed74mnd]

Finally got the bike going last night ( much to my neighbours delight heh) overhauled the 38’s with new o-rings and emulsion tubes. Unfortunately its running very lean at the moment, but ive got some bigger mains to put in, only had the carbs off about a dozen times so far, so another dozen times to get it right wont hurt. Will try the factory pro recommended 152.5 jets (thx J7/11) and then go thru the jetting procedure from there.
Bike handles well with the USD front and 180 rear… heaps of fun!

Cheers

Ed

[TurboKat]

Are you running the standard airbox or pod filters Ed?

[Ed74mnd]

hey turbo,

i'm using K&N oval pods.. not sure of the exact part #.

pissed the airbox off, coz i took the side panels off and have un cluttered the mid are of the frame. kinda like the yoshi katana.

Cheers

Ed

[TurboKat]

Oh dear [V]
I've done the same thing many times in the past, as you've probly already worked out, the std. airbox causes much resriction, when you piss it off, the bike runs MEGA lean all through the rev range due to all the extra air that's suddenly become available, I've had the carbs off GSXs so many times it pains me just thinking about it :(
What I found out in the end after much trial & error, talking to racers & "experts" was that when you take the airbox off, the std. 33mm CV carbs can't supply enough fuel to match all the new found air flow. You basically have to set the carbs up as rich as possible on all the circuits to get them to run anywhere near right. It can be done, but unless you set it up on a dyno, you'll never get it spot on by plug chops & seat of the pants & if you're like me, you'll always be worried that it's too lean & you're about to melt a piston.
From experience, set the needles up maximum rich (lowest clip) & tune the mains from there. Good luck with it.

[Ed74mnd]

it aint so bad Turbo.

i got 38mm slingshot carbs! sold the original ones to a restorer.

they supply plenty of juice.. sometimes too much!

Cheers

Ed

[Ed74mnd]

oh and i have put a AF meter in the exhaust to help me tune.

no plug chops... just read the meter at various revs and loads.

Cheers

Ed

[TurboKat]

Beautiful, A/F meters are a blessing eh?
38s are probly a bit ambitious, I always wanted to try 36s on mine coz they bolt straight up but back in those days, there weren't many around.
Sounds like 36s might be the go for yours, see if someone on here wants to do a swap maybe?

[shift1313]

very cool project. great job on the bracing as well. Looks like you dont have much room between the tire and the front of the arm. what happens when the tire deforms under load? Is that a 6" rim of 5.5" rim. Thats a tough call on the frame. remove the rear and start over:) you look as though you have the tools and the skill.

[Ed74mnd]

hey Turbo,

38's are the business for these motors.

i got the jetting sorted and it has woken up the old girl like you would NOT believe.

pulls like a freight tain from zip to redline.

At idle the mix sits right on 14.7:1, and throttling thru the range reads lean. I’m guessing this is normal. At cruising around 3,000 rpm it reads lean too. If I pull the choke out 1 click or 2, then it instantly bogs down indicating too rich although the meter doesn’t really register this. There are no flat spots.

Shift, the tyre has a fair amount of room up front 5mm maybe each side to tyre. Everybody told me id have to chop out the front of the swinger but it doesn’t need it. It’s a 5.5 inch GSXR rim.
Body wise I’ve put the original rear end on it for now, so I can ride it. Plans are to change out the tank and rear end to have a more café racer look about it, but
It looks good on the road now, it is long and low with fat wheels.

will post a pic shortly.

Cheers

Ed

[TurboKat]

Good stuff Ed, glad to hear it's sorted :)
Coming to the Fools? I wanna see this thing of yours.

[Ed74mnd]

wont be at the Fools run, I will be OS, otherwise I'd be there...

Cheers

Ed

[Slingblade]

Gday Ed,

As i posted elsewhere i have a mate who has gotten a gsx1100 and is looking to do something similar to you, with a USD front end and 5.5 rear in the standard swinger. He is not on the net so i was hoping to drop you a line if thats alright and get the mail on what problems and shortcuts you have run into. If this is ok let me know. Any help would be appreciated.

cheers

Nath

[Ed74mnd]

no probs,

i've sent u an email.

also the biggest prob was waiting for parts!

it's a bit of a no- brainer with lots of info on the net, and relatively easy to come by parts.

of course you could spend a whole lot more $$, make custom parts and have a truly one-off stunning machine, but that wasn’t my objective. I just wanted a “cheap” tuff old bruiser of a bike.

Cheers

Ed