Building a GSX1100ET for flying mile and a bit of drag racing

[megawatt]

Over in the Uk recently was a programme called Speed Dreams in two one hour episodes. Basically it was about 6 British bike builders who built bikes to do the land speed records meeting at Bonneville in Utah.
Well as an ex drag racer, it gave me a bit of a nostalgia twinge and I contacted PJ, featured in the doco riding a GSX1100. He is organising a meet at Pendine Sands in South Wales( not the New one) and I thought, I'll help with the organising and go and watch. Then I thought, why not build a bike?
I posted an interest on Brit Chopper Forum and on various Facebook pages. A new friend called Tony Cosmo Calliandro said he had some GSX chassis parts and for a modest fee I could have them.
I was straight up there, only 20 miles and we filled up my Passat. Here's the stuff on my drive.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1167.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1166.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1165.jpg
Think I will go with the ET/ESD frame instead of the EFE frames. Threw a few parts on it for a laugh;
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1182.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1183.jpg

[megawatt]

I got some great offers from people I've never met on the OSS Facebook group. Drove up to Waltham Cross on Saturday to meet an OSS stalwart called Ian Foxon. Had a brew and drove to his workshop , where we unloaded some goodies from me to him. Main one being a very old, very small, lathe that needed some brackets making and the drive motor mounting to make it work. Once we'd unloaded the Passat and stopped admiring the Katana and EFE in his workshop, we drove to his lockup in Barnet. There, he presented me with a virtually complete GSX1100 engine. It turns out it wasn't just any GSX 1100 engine. It came with a standard EFE cylinder head( bigger valves and ports than the earlier engines). We then went to his mums garage, where he gave me a rusty Harris exhaust system, a Bandit 1200 swingarm and an undamaged ET headlamp unit.

Well , I managed to unload the parts and got to work stripping the engine for cleaning and checking. The good surprises just kept coming!!!

http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1267.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1259.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1261.jpg

GSX1100ET headlamp and lockup clutch with crankcase extension!!!
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1262.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1265.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1266.jpg

Standard GSX1100 clutch baskets are known for turning into tambourines and eventually exploding when used in tuned drag race engines. This is compounded by Suzuki fitting helical drive gears to the clutch and crankshaft. The solution is to replace the gears with straight cut gears and the clutch backplate with a billet steel one. All riveted together and the rivet heads welded to the backplate. This mod would normally cost at least £300 to £400 !!!

http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1268.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1269.jpg

Another drag race mod is to replace the standard GSX oil pump gears with GS750 items. These run faster, providing more oil for cooling!
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1271.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1272.jpg

[megawatt]

Found a bit of time to split the engine last weekend and have a look inside. Started by removing head and block, alternator and ignition covers. Then remove anything inside the engine that stopped the top and bottom halves being seperated. At the back of the clutch are a couple of retaining plates that need removing and another one that needs the oil ways blasting through with degreaser and compressed air.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1267.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1280.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1281.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1282.jpg

Then it was time to remove all the M6 and M8 bolts from first the top half
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1276.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1277.jpg
.
Then the bottom half.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1284.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1285.jpg

The engine is normally split with the top half upside down on the bench, retaining the crankshaft and gearbox in place.

Next job was remove the fabricated sump and undo the main bearing bolts hidden inside. Note; the sump fabricator has put his initials in there, a good sign.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1286.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1287.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1288.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1289.jpg
sump filter was nice and clean. Also housing modified for racing.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1290.jpg

Removed the last two M8 main bearing bolts and tried to seperate the two halves. No joy!!! Did anyone spot the deliberate mistake?
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1279.jpg
Look at the right hand side of the gearbox? Yep, left an M6 allen bolt in there!!!! Removed it, flipped engine over, couple of taps with a mallet and voila!
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1292.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1294.jpg

Found one slightly galling problem when I split the casings. A small piece of loose aluminium in the top half.

http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1296.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1297.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1299.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1298.jpg
It's the cam chain guide holder, but I can fix or replace it. Other than that, all looks pretty good.

Later I started cleaning gasket goop off the sealing faces and cleaning up the M6 threads.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1295.jpg

[megawatt]

Haven't made much progress this last week, too much DIY to do, to keep the peace. Yesterday I decided to clean up and check the crankshaft, rods and bearings.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1331_zpsdac57f60.jpg
First I cleaned all the rust off the rotor. Not sure I'll be using it as I ran my last race bike with total loss ignition. May not use the starter ring gear and motor either to save weight
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1332_zps3e1ebea4.jpg
Then I blasted out every drop of chainlube that I had used to protect the crank from rust. Blasted brake cleaner at all the bearings and oilways, checked them for clicking and stiffness and then re-oiled the lot, wrapped in bubblewrap and stored safely outta the way.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1333_zps75adcbcf.jpg
Then I started the boring , but essential task of removing the old gasket sealant, gasket and any high spots from the crankcases. Still not finished , but making slow progress.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1334_zps486597bd.jpg
A lot more cleaning to do , but I am still waiting on the camchain tensioner support bracket from Robinsons, all the way from Japan.

[megawatt]

Been talking to some very helpful people today and have been offered an extended swingarm 5.5" rear wheel and a dragpipe.
I may be having a go at making a swingarm myself outta mild steel box section. watch this thread. Anybody else out there with an ET dragbike, advice welcome.

[Gix11]

Now that's what I call a build topic. Brilliant mate. Thanks.

[megawatt]

Thanks for your interest mate. This will be a cheap build, as I am retired now and I can't afford expensive drag parts. We will be riding on sand at Pendine, so traction isn't important, but I will be lowering the gearing to do some 1/4 miles to shakedown the motor. I want this to be a lightweight chassis with a strong, stockish engine.

[ozzy1100]

Mmmmmm old sckool air cooled even if it is a smelly Suzy
Will be following this build

[Tony Nitrous]

Thanks for posting it up in here,
I've been following it and was sure that some
folk on here would be interested.
Very interesting.

[Yella]

Nice will be watching this

[stiffsimon]

Wow you jammy, jammy sod you. All that lovely GSX goodness bestowed upon you.I thought initially that you'd been granted access to that hallowed place called aircooled wunderland after speaking to PJ but maybe later,eh?

This looks like an awesome build and you've got some excellent stuff already to get you up and running and some pretty bloody good contacts too by the look of it.

You're a man after my own heart and have chosen the correct GSX model to use as a base. I too favour the early ET GSX models and am doing a little bit of a freshen up on mine

http://www.streetfighters.com.au/forum/showthread.php?13298-GSX-1260-project.-Making-it-better-Fuck-yeah

With the cam chain tensioner the problem that you discovered when ripping the engine apart is not uncommon on these motors. Apparently the shape of the rear cam chain guide is to blame. Apparently the shape of the end of the blade allows the chain to "drop off" the blade causing resonence in the chain which causes vibration which eventually causes the mounting bracket to fracture. There is a company in USA that manufacture a cam chain blade out of nylon which eliminates this problem.

I can't remember who these people are but Peter McWiggan from Manta Enterprises http://mantaent.com.au/ here in Melbourne would be able to help you source one.

PS don't mind Ozzy 1100 he's still to see the light yet and favours those old green dinosaurs of the Zed variety. I'm hoping he'll "adjust" at some point in the future

[megawatt]

Thanks for the encouragement gents. Yella, I am following your Busa build with interest. Don't get hung up on power though! I had major success with my streetbike coz it weighed nothing. If you went the race only route, there is a lot of scrap metal you could junk.
Thanks Simon, I have ordered a new one now, but it's coming from Japan

Here's some pix of my old Streetbike and Pro Stocker, using them for inspiration.
http://i145.photobucket.com/albums/r240/megawattblade/My%20Bike%20pix/My_GSX-1.jpg
http://i145.photobucket.com/albums/r240/megawattblade/My%20Bike%20pix/File0002.jpg
http://i145.photobucket.com/albums/r240/megawattblade/My%20Bike%20pix/File0004.jpg

[Gix11]

Do we have a circa date for those photos?

[megawatt]

Yes mate, raced the streetbike in 1983, the stocker from 84 to 88.

[megawatt]

Not had much time in the garage recently , but I managed an hour today. I was given 4 camshafts to clean up and use. They looked like this;
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1356_zps8e6d1ce9.jpg
Gave them a clean with some WD40 and a nylon/carborundum rotary brush and spotted a couple of interesting mods;
Can you spot them/
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1357_zps31e6449c.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1359_zpse36fa754.jpg
and this;
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1362_zpsfed40100.jpg

[K6Thou]

Slotted sprockets....

Liking this mate, keep the updates coming.

[megawatt]

Good spot mate. and the last picture?

[stiffsimon]

Er no wear on the cam lobes?

[megawatt]

Wasn't sure if they were ET or EFE cams. The lack of tacho drive worm on the exhaust apparently confirms it's an EFE cam and I got more valve lift!!!

[K6Thou]

Wasn't sure if they were ET or EFE cams. The lack of tacho drive worm on the exhaust apparently confirms it's an EFE cam and I got more valve lift!!!

Good score.

[megawatt]

Well not much progress recently, too much DIY to do! Anyway, I received a parcel this morning:
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1406_zps1e9c5f15.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1407_zpsbd7e58b7.jpg
Can you guess what it is yet???
Couldn't wait to get rid of the packaging . Here it is, made to fit a GSXR1100 Slabby dragbike.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1413_zps0ae6b42a.jpg
And next to a stock Bandit 1200 arm. 10" longer than a stock arm
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1414_zpsd4659107.jpg
Had to widen the frame a bit to fit it in. Will be making correct size top hat spacers to fit the stock bearings.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1417_zpsf7b3f137.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1416_zps0448fe83.jpg
Fitted swingarm spindle and arm into modded frame and tried a spare 17" by 6" Triumph wheel, with 200mm tyre, that I happened to have lying around. Won't be using this combo though!
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1418_zpsa7579201.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1420_zpsc85f3dd2.jpg
Only managed to lower the front end about 3/4", should be about 4" lower eventually.

[Yella]

Niiiiiccccceeeee

[megawatt]

Cheers mate. Hope you're making more progress with yours.

[megawatt]

My wonderful wife overheard a conversation about my racebike. I have been offered a free paintjob and want it in it's original Deuce colours, as raced in Pro Stock by Pip Higham. She ran upstairs and found a copy of Superbike magazine from December 1980.Hopefully here is the front cover;
http://i145.photobucket.com/albums/r240/megawattblade/Deucecover_zps6bbfe75c.jpg

[megawatt]

Well it was raining all day today , so I completed a job on somebody else's carbs and then started work on the racebike cylinder head.
Gave it a quick clean with a plastic fibre wheel in my drill.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1444_zps725f3735.jpg
Cleaned up the exhaust threads.
Then before I removed the valves, I thought I'd check how well sealed to the head they already were. I poured paraffin into the inlet and then exhaust ports and then checked the combustion chambers. No paraffin at all.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1446_zps750f0c85.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1443_zps87e3d4cc.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1445_zpsdeb4680a.jpg

I removed the paraffin and then thought I'd have a look at the valve seats anyway. I found the valve spring compressor that I'd bought 30 years ago to work on my original sprint bike.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1447_zps1db4606e.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1449_zps335bca7b.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1450_zpse6ecfc53.jpg
Sure enough, the valves had recently been lapped to the head. Saving me a normally laborious job.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1451_zps450d1355.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1453_zps513e64eb.jpg

With the inlet valves out, I felt around the area where the valve seats meet the head and there was a ridge on both valve ports.
I set up my Dremel type tool with it's flexible drive and ground the seal and head until there was no step all around it.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1454_zps801dce60.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1455_zps7c8d02d8.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1457_zps98a447e8.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1458_zpsf96ea4b8.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1462_zpsbe41863f.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1464_zps0db152fa.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1470_zpsff6e3d84.jpg

Was going to clean up the casting marks in the inlet ports , but it's already been done!
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1459_zps69ce4d1e.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1465_zps1a2e3ee4.jpg

I know I should grind the tops off the valve guides and blend them to the head, but I'm not that skilled with the grinding tools and I don't wanna risk doing any damage.

[megawatt]

Just had an eMail from Pendine Landspeed Racers Club. My entry has been acceped. I'm in!

[ozzy1100]

Sweet :-)

[MattyDucati]

Comin along nicely mate

[megawatt]

Cheers chaps.

[megawatt]

Had a bit of time in the garage today. I donned my thermals and decided with a bit of encouragement, to grind the tops off the valve guides and blend them into the head. Mainly used small emery tubes on my Dremel , but had to resort to small grinding wheels at one point to remove enough steel from the valve guides. A bit more work to do , but I was sneezing too much and my snot was freezing on the end of my nose.
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1481_zps1a6b1d1c.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1480_zps34636af2.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1479_zps5e5c026a.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1484_zpsf84ac4a4.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1482_zpse9630900.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1477_zpsa8947825.jpg
http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1478_zps7e5b7849.jpg
Managed to blend most of the ally around the stems , but need a bit more alloy removal before they're finished.

[megawatt]

Well not a lot of progress this week. Dry weather , so been up the scaffold doing some cladding work.
Got two parcels today and a small parcel earlier this week.
Two swingarm spacers for the Gixxer 1100 arm fitting to ET frame.

http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1487_zps84199312.jpg

5.5" Gixxer 1100 rear wheel, complete.

http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1491_zps60aedd13.jpg

Star Racing 4 into 1 system and ET tail unit and light.

http://i145.photobucket.com/albums/r240/megawattblade/All%20bike%20pix/GSX1100%20project/IMAG1490_zps8b7e73ec.jpg

Thankyou very, very much to some very generous guys in the west country and Northumberland.

[Gix11]

Win! Good to know somebody cares about your project. One step further....

Ahh Northumberland. Always reminds me of the roller coaster roads and the cops waving me past at 110 MPH. Hope things haven't changed that much in the last 20 years.

[megawatt]

Wish I was a bit closer mate. I'm stuck in southern softieland with these heathens. Been well impressed with the help I've had off total strangers. Mind you, it's all the small bits I need that will ramp the cost up. £200 so far!!!