Gonna build a Flying Mile GSX1100

[Tango]

Nice one Alan....glad the project is moving along..... Looking forward to following the build on this mate....

[megawatt]

Should make some progress next week mate.

[megawatt]

Made some progress this weekend. Got talking to some of the guys featured in the BBC2 documentary Speed Dreams and some guys on the Oldskoolsuzuki Facebook group, said I was gonna build a flying mile bike for Pendine sands and got some great offers from people I've never met. 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 today 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

Edited February 12, 2013 by megawatt

[Tango]

Hey, good result Alan......looks like you struck pay-dirt there mate.....

[megawatt]

Kin ell Bob, just checked on Orient Express website. Straight cut gears , $600, billet clutch , $600 !!!!!

[Tango]

Shhhhhhhhh!......he may want it all back......

[Stu]

Is this going to be ready for the rally then Alan?

[megawatt]

Well Pendine Land Speed Records event is scheduled for June 20 to 23rd. So , Yes, hope so

[megawatt]

Found a bit of time to split the engine today 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

More tomorrow or Thursday !!! Phew!!!

Edited February 12, 2013 by megawatt

[Fozzie]

I quite like the look of the internals of this bike!

Looks like a lot of work but nothing overly complicated

Keep it up!

[megawatt]

I've stripped and rebuilt engines in the pits at Santa Pod! Lovely engines these aircooled Suzukis. No bloody shell bearings to faff around with!!!! As long as the crank bearings are OK

[megawatt]

Haven't made much progress this last week, too much DIY to do, to keep the peace. Today 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.

Edited February 12, 2013 by megawatt

[Tango]

Nice work so far Alan......looks like you're making some progress.....

[megawatt]

Gotta do it in secret when the wife's at work and I've done some DIY. . She thinks it's gonna cost a lot of money and time. It's cost about £100 so far! Got a bit more cleaning and prepping to do while I wait for the cam chain tensioner support bracket.

Had a long chat with Brett in Newcastle this afternoon. He is gonna courier a stainless extended swingarm, spindles, 5.5" rear wheel , struts, and a race exhaust system. Gonna loan them to me and turn up at a couple of meets to watch how I get on.

[Tango]

Bl**dy hell mate....I can't believe that amount of stuff you've blagged for this bike.....

[mealexme]

wow! Thats quite impressive! what sort of times are you looking to get on the sands?

And whats the average sort of times on sand? I didnt realise they did events on Pendine tbh. (unless someone is going for a record or something)

[megawatt]

I have no idea what is achievable on sand, certainly not low ETs. The engine is a stock 1135 EFE with a race bottom end and clutch. I don't expect a lot on the sand to be honest. There is no traction off the line and a very long way to travel. GSX 1100 top end was around 130 to 140 mph. I will be doing some shakedown runs at SCR and Santa Pod, with 1/4 mile gearing. I hope to achieve some low 10 second runs on it. My "road legal" bike managed 10.37 at 137 with a 998cc engine, air shifter , big carbs and slightly higher lift cams. If I can scrounge some go faster bits for no money, I am a pensioner ya know, or some nitrous bits, I hope to run low 10s at over 140mph. Remember the terminal speeds are at the end of a 1/4 mile, not top speeds.

If anyone has some spare cash, I'm sure I can put it to very good use. I have been offered a turbo kit, nitrous kit and a supercharger!!!

[Tango]

Unfortunately all our cash is tied up Alan.......but let us know when you are planning to go to the Pod and we'll get across to see you.....

[megawatt]

Will do mate. Just got off the phone to another adviser and there's a strong chance that I will be fabricating an extended swingarm!!!

[megawatt]

Probably not making a swingarm now! Just done a deal on one, 10" longer than stock , for very little money. Oh! and a complete 5" wide by 17" rear wheel and tyre , for even less money. Happy days

[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

Edited February 19, 2013 by megawatt

[acting_strange]

Do you mean the slotted drive cog...thereby making the valve timing adjustable?

[megawatt]

Yep , the SPROCKET bolt holes have been elongated to allow adjustable valve timing. More evidence that it is a race engine.

[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 6" lower eventually.

[Tango]

Looks like it's still coming along nicely Alan......looking forward to seeing some vids of it running.....and maybe seeing it run in the flesh up at the Pod......