|
|
Post by captain chaos on Nov 11, 2014 19:30:39 GMT
Hi, my mate/colleague/allround good bloke Tomas has bought an 1100ESD a few months ago, with the intention of modifying it heavily. He tried my EFE/B12 thing one day and said "f*ck Harleys, this is cool, I want one". So we pushed his Electra Glide (which was 90% complete) in a corner and started modifying the GSX. When we got the bike it was running not badly, but it looked tired. It had a GSX600F seat and tailpiece but everything else was more or less stock. It just needed a lot of TLC. So Tomas bought a vrey rough GSX-R750W (which happened to have an oilcooled 1100 engine), took the complete front end and rear wheel, and sold the engine to another mate of mine. A few hours of spannering later the front end was swapped, rear wheel installed, and all the other stuff removed. Now we had a bare frame + engine + running gear. Fast forward a few weeks (and some holidays for me). Yet another mate had modified the frame rear end, modified the exhaust, and done a few small things. After powdercoating the frame and painting the engine, it looked like this:   |
|
|
|
Post by captain chaos on Nov 11, 2014 19:37:55 GMT
The speedo, headlight, taillight and turnsignals came from Louis in Germany (we can get a good deal, and free delivery). We painted the engine with Crafts rattlecans, the result is great. All the bolts were then replaced with nice 'n shiney ones. The right side crankcase cover is ordered new from Suzuki and should arrive any day now. The rear brake hanger is from the GSX-R, the swingarm had a lip welded in it so a torque arm is not needed.   Shock extensions are also made by the other mate. I suggested to have them rounded nicely but Tomas doesn't want it, he like iit like this.  |
|
|
|
Post by captain chaos on Nov 11, 2014 19:43:32 GMT
The exhaust is made from the original headers, some mate-made link pipes, and two silencers bought from a local exhaust dude. We had the bike running with this system and it sounds good.  The wiring loom has been simplified by me (monitor unit and a lot of useless crap removed). Only the most essential stuff is there, just enough to make the engine run and the lights/speedo/horn work.   Stay tuned for more about the "old sledgehammer" as Tomas calls it. |
|
|
|
Post by busaash on Nov 12, 2014 8:33:14 GMT
that build is coming along nicely captain  |
|
|
|
Post by captain chaos on Nov 12, 2014 12:39:35 GMT
Fired it up today, and found out that the engine is leaking oil where the crankcases meet, near the oil filter cover. Maybe it was leaking eralier, but we didn't notice because of the stream of oil coming from the (lack of) rocker cover gasket. We fixed that, painted the engine, and now it's wet again.
So now the engine is being removed. Actually it's good that I open it up now, I found the clutch nut unscrewed, the generator cover had no gasket, and God knows what else waits inside. It was running nicely (although a bit noisy at idle) so it can't be too bad.
|
|
|
|
Post by gsx on Nov 12, 2014 13:24:48 GMT
Looking good mate , are the shock extensions to be welded as well ? Thought bout doing same on mine but wouldn't have thought the 2 bolts would stop them moving around
|
|
|
|
Post by captain chaos on Nov 12, 2014 17:35:35 GMT
they are not to be welded.
We haven't tried riding yet, no brakes and no engine at the moment, only time will tell if it moves.
|
|
|
|
Post by arnout on Nov 13, 2014 18:45:37 GMT
Hey.. A CC-ESD project build thread! Nice job on the wiring.. It seems you've found the best compromise between doing quick fixes and building a new loom from scratch.. Before or even while taping (best use non-sticky stuff) it is handy to put the loom back on the bike so you can better place/check the position of the "branches" and pre-shape the whole thing following the lines of the frame and such.. Because if you tape it up on the workbench you're stuck with a very stiff cable that is very difficult to nicely fit onto the bike.. Fired it up today, and found out that the engine is leaking oil where the crankcases meet, near the oil filter cover.. That's a bummer..! But isn't this the engine with the cracked cases (you epoxied up) ? Fired it up today, and found out It was running nicely (although a bit noisy at idle) so it can't be too bad. Well the "noisy" idle is prolly due to the loose clutch nut.. ("They all do that, sir"  ) Still old GSX's often rattle at idle because of saggy springs in the primary gear and/or increased space between moving parts of the clutch on the shaft.. Btw.. The paint on the engine and frame looks really nice (what type/brand did you use?) Not sure about the exhaust though.. although it looks fine and is tucked away nicely, such small silencers make me frown a bit.. Either it is really loud OR really stuffed full with baffles severely limiting the flow.. Either way is fine by me (hey, do as you please / it's your bike/ etc ) but it is far from being a "performance" can.. Which is fine of course if you don't mind.. Had a bit of a "deja-vu"-moment with spotting the shock extensions earlier as I had some on my GSX many years ago too as a low-budget fix.. Not the finest solution, but hey if it works, why not..  |
|
|
|
Post by captain chaos on Nov 13, 2014 20:55:43 GMT
Yo Arnout.
The frame is powdercoated, the engine is painted with rattlecans, Crafts spray from Holland. An engine building mate recommended it, it's fuel resistant, and holds really well on an EFE rocker cover I did a few years ago.
Today we painted the carbs (gloss black), will be interesting to see how well that holds.
Yes the crankcase has a crack in it, we glued it, and it's not leaking there. After splitting the cases I found some places with a lot of sealant and some places almost without any. Gearbox, crankshaft/rods and oil pump are in good condition, primary gear springs are a bit loose, nothing serious.
Of course I put the loom on the bike and taped it up a bit before removing it again and completely taping it.
By the way we wanted to order gaskets from Suzuki (clutch cover and generator cover) but apparently they are no longer available. Is this true? Where do we buy some now, or do we have to make new ones ourselves?
|
|
|
|
Post by captain chaos on Nov 13, 2014 21:06:21 GMT
this paint:  |
|
|
|
Post by arnout on Nov 14, 2014 20:02:37 GMT
..the engine is painted with rattlecans, Crafts spray from Holland. Ah.. I vaguely remember somebody once mentioning this paint to me before too.. Maybe that was you?  ..Gearbox, crankshaft/rods and oil pump are in good condition, primary gear springs are a bit loose, nothing serious.. Well.. It's nice to be able to have a look at the internal parts while needing to fix the crankcase seal leak.. Yup.. Some slop of the primary gear springs isn't too bad (quick fix: fill space with washers).. Also have a look at the wear on the 5th gear while you're at it, and don't forget to clean out the coarse filter in the oil pickup.. By the way we wanted to order gaskets from Suzuki (clutch cover and generator cover) but apparently they are no longer available. Is this true? Where do we buy some now, or do we have to make new ones ourselves? Nope.. Readily available.. Here you go.. |
|
|
|
Post by swirl on Nov 18, 2014 4:11:43 GMT
Paint looks great buddy
|
|
|
|
Post by captain chaos on Nov 26, 2014 16:41:41 GMT
Lil' update split the crankcases, had a good look inside, rebuilt the engine and put it back in the frame.  We received the complete ignition cover (right side crankcase cover) and the generator cover logo, both new from Suzuki. Now the engine looks amazing and can even keep the oil inside (we hope).   Carbs painted, also with Crafts rattlecan  and a detail of the frame. Seat lock is integrated in the pipe, with a little push button to operate it.   |
|
|
|
Post by rusty on Nov 26, 2014 20:59:44 GMT
Looking smart:-)
Nice touch with the seat lock too
|
|
|
|
Post by captain chaos on Nov 27, 2014 11:20:28 GMT
Fired her up this morning and the engines incontinence problems seem to be cured.
Now I can tidy up the wiring, and finish all the fiddly bits.
|
|
) Still old GSX's often rattle at idle because of saggy springs in the primary gear and/or increased space between moving parts of the clutch on the shaft..
