BeardedBaldys Touring Spec GSXR1100

[Bearded Baldy]

Tyres are past dated.

Thought has been had already, multiple times.......

[Bearded Baldy]

Todays mission is to check over the california spec PAIR emmisions control system and ensure it is working properly. And repair anything that doesn't work properly.

 

 

 

 

 

 

 

Just kidding. It is getting removed with extreme prejudice!

[Bearded Baldy]

And i got distracted.

The cracks in the tail have been in the back of my mind since i first saw them on old mates driveway.

So today i tried the internet gospel of glueing abs together with acetone.

And it works! Light brush of acetone one both edges and squash together. Then brush some over the back side and squidge it all together.

Obviously still leaves a crack line but the bond seems pretty strong. Now to find a scrap piece of abs and put it across the back for extra strength.

And give the rest a polish up.

[Bearded Baldy]

Not too shabby at all. Can still see where the cracks are, but they aren't going to get any bigger.

Now only the front mudguard, upper fairing, and  frame to go.

[Bearded Baldy]

Went and hung the tail in the shed with all the other bits. Saw the 2 pieces of the packframe sitting there and decided there was enough time before dinner to get into that aswell.

When joining bits of tubing like this, i like fitting a bit of steel rod to the inside and plugwelding it to both halves. Unlike the last guy as it snapped through his welds.

Bit of zapzap on the custom stone workbench aka driveway.

And a run over with the flapdisc to finish off.

Time for some black zincit because grinder and paint hides the welder i ain't.

[Willdat?]

18 hours ago, Bearded Baldy said:

And i got distracted.

The cracks in the tail have been in the back of my mind since i first saw them on old mates driveway.

So today i tried the internet gospel of glueing abs together with acetone.

And it works! Light brush of acetone one both edges and squash together. Then brush some over the back side and squidge it all together.

Obviously still leaves a crack line but the bond seems pretty strong. Now to find a scrap piece of abs and put it across the back for extra strength.

And give the rest a polish up.

You can also dissolve a piece of abs in a jar of acetone, then use it as a colour matched gap filler. 

[Bearded Baldy]

2 minutes ago, Willdat? said:

You can also dissolve a piece of abs in a jar of acetone, then use it as a colour matched gap filler. 

Good to know!

[Bearded Baldy]

Cleaned up and polished the frame, mostly so i could put the tail back on, leaving it hanging off the rafters was making me nervous.

Also did the rest of the yellow on the front.

This going to pop once it makes it back out of the shed!

[Bearded Baldy]

PAIR system removed!

Filthy California hippies and their cleaner emissions regs. Not on my watch!

Now to make a set of blanking plates, the temptation to thread the holes and plug them is very strong, but even with the radiator hanging, there is not much room to work with.

[Bearded Baldy]

[Bearded Baldy]

Oh no.

However did that happen....

[Bearded Baldy]

So it turns out that the jet kit i ordered which was apparently in stock at the suppliers supplier, was not.

Have been waiting since mid march but i got the tracking email last night from MickHone in aussie so they are on the way, muffler is en route from Christchurch too.

Just realised i have not ordered a decent air filter yet so i had better get onto that.

Off to see what obsolete listings are out there....

[Bearded Baldy]

Jet kit and emulsion tubes and emulsion tubes got delivered to work this morning according to the tracking.

Muffler should have arrived too, hopefully my neighbour drops everything off so i can start the reassembly process.

In the meantime, may as well start polishing the brackets and whatnot.

[Bearded Baldy]

Productive evening for a change.

I must be part magpie because i love shiny stuff!

[Bearded Baldy]

And the FactoryPro kit.

Pretty basic, new plunger springs and circlips for the needles is a nice touch, was not looking forward to swapping the clips with my clunky fingers.

Looks like they bumped me up to the titanium needles too to apologise for the 2 month wait.

Managed to cross reference the o.e emulsion tubes to another later suzuki number so grabbed 4 of them too. 

Lots of info and a starting setup guide supplied so will have a read and go from there.

Then worry about small things like the clutch and brakes, forks, etc etc.

[Bearded Baldy]

Went to mount up the muffler and triple check it is correct this morning. Someone has stripped out the 8mm threads and made a real hash of trying to rethread it. Have now cleaned that issue up and retapped to 10mm, which means now i wait to fit things as i don't have any 10m stainless capscrews in the hoard.

Not wanting to waste the hobble out there, i lubed the throttle cables and gave the pilot jets another soaking, will give them a brush out later and dry them off ready for next weeks job of reassembling the carbs.

Presoaked the midsection clamp on the exhaust ready for removal too. Will make a plug to blank off the lh tailpipe once i know for sure what size it is on the inside.

 

[Bearded Baldy]

Here we go again,

Very impressed with the Litetek gasket set, quality is awesome and has every last little piece, down to new washers for the pilot mix screws.

Although, CS-008, you can go fuck yourselves. Choke plunger seals, managed to get 2 out using a fish hook. Other 2 can wait for another day.

Ordered some stainless capscrews etc for the housings and the exhaust which should turn up this week.

[Bearded Baldy]

Has been too cold and miserable out in the shed lately so yesterday i brought my trays of parts inside and got back into the carbs.

All back together as a set now, no major issues, and only one minor one.

Well two really as 2 of the 4 float needles had stuck springs. Managed to grab the pin with 'definitely not the wives' toenail clippers, and with a bit of twisting back and forth eventually cleaned all the rust and smout out of them.

Set the floats to 15mm as per the jet kit instructions. Used the 120 jets from the kit and set the jet needles on the second slot to start with like the cheatsheet suggests as a starting point. 

[Bearded Baldy]

Thanks to OSGC @HumberSS who kindly plasma cut some bits of aluminium plate for me. 

The small ones are the blanking plates for the PAIR emission ports above the header flange on the head. Still need to cut some gaskets then can play the fiddly game of fitting them without taking out the radiator.

The other bits are to make a new stoneguard for the oil cooler as the old one was bent/rusty and generally ugly.

Some of the worst freehand drilling i have ever done, but coupled with some ali express alu mesh, i now have this.

Next trip to town i will grab some 2mm capscrews and finish it off. 

And yes i will have 2 next to each other in the middle. That mistake was the first hole!

[Bearded Baldy]

And some futher confirmation of where we all knew the clutch fluid had gone....

Spotted while taking the left hand exhaust assembly off. 

Started making a plug to seal off the exhaust branch but i need a new belt on the lathe. I have been milking it for years so i was not surprised at all when it spent more time slipping than spinning this afternoon.