Rebuilding a bike from ground up

[doubl3mint]

Hi all

 

I've just taken possession of a '95 Gixxer 1100, and i'm thinking of doing a full rebuild, totally stripping the bike apart and putting it together again, changing whatever parts necessary in the process.

 

I was looking at some of the rebuilt 1100's online and its inspiring. But they're mostly ang moh's, and i'm unsure of any local resources available to me.

 

Do any of the bros here know of any shops that specialize in such projects, or have any contacts I can ring up (mechanics, parts, etc)?

 

Feeling somewhat clueless at this point, as this is my first such project. thanks in advance!

__________________________________________________________________________

 

in case anyone else needs it, here's the factory service manual!

 

http://www.scribd.com/doc/3098570/Suzuki-GSXR1100W-9398-Service-Manual

 

more links to bike manuals here!

 

http://www.sportbikes.net/forums/suzuki-sportbikes/322830-service-manuals.html

Edited September 21, 2010 by doubl3mint
found link to service manual!

[cougar]

U mean you ask local bikeshops to rebuild for you or you looking for parts to rebuild yourself?

 

Most bikeshops do not have the time nor willing to spend the time to rebuild one bike fully, they can make more money doing ad-hoc jobs, and maintenance jobs.

 

And the skill level for big bikes i am also doubtful, its better if you get hold of Hayes or Clymer manual for your model and ask them refer to it if encounter problems.

 

Even if rebuilding yourself, you need proper bike tools, like engine lift jack, for such a big bike, needs lots of space even for a small garage. That model is carb or ECU? You need diagnostic tools as well.

 

I think probably end up cheaper buying a new bike or good condition used bike.

 

But if you really serious into it, I did go to Gerry Looi's at Tampines St 92, the mechanic Amir worked for 20-30yrs there repairing, rebuilding sports bike, the owner was a retired racer. Seen them fixed Beemers, Gixxer, Yamahas, Hondas.

[doubl3mint]

hi cougar, thanks for the prompt reply! i dont think i have sufficient knowledge to do it all on my own, was planning to get a shop to do it for me and perhaps i could be involved in the acquisition of parts from overseas or any ad-hoc errands they might have me do, haha!

 

but i guess it might be too optimistic to think there could be a place like that in singapore, from the look of it?

 

as for Gerry Looi's, are you talking about mr amir?

 

btw, the gixxer is a carb model, pretty old bike.

 

anyway, here's a few threads regarding such projects, for anyone who's interested!

 

http://www.gixxer.com/forums/showthread.php?t=222357

http://www.customfighters.com/forums/showthread.php?t=19908

 

http://www.flickr.com/photos/36052405@N05/

 

i would think there'd be a sense of ownership and pride at having a machine like that, something you had a part to play in creating!

 

still looking forward to any input and suggestions any of you bros might have =)

Edited September 20, 2010 by doubl3mint

[Metal_Heart]

hi cougar, thanks for the prompt reply! i dont think i have sufficient knowledge to do it all on my own, was planning to get a shop to do it for me and perhaps i could be involved in the acquisition of parts from overseas or any ad-hoc errands they might have me do, haha!

 

but i guess it might be too optimistic to think there could be a place like that in singapore, from the look of it?

 

as for Gerry Looi's, are you talking about mr amir?

 

 

anyway, here's a few threads regarding such projects, for anyone who's interested!

 

http://www.gixxer.com/forums/showthread.php?t=222357

http://www.customfighters.com/forums/showthread.php?t=19908

 

http://www.flickr.com/photos/36052405@N05/

 

i would think there'd be a sense of ownership and pride at having a machine like that, something you had a part to play in creating!

 

still looking forward to any input and suggestions any of you bros might have =)

 

Bro try finding a thread by "Marchline" (think thats his name) he rebuilt his R1. maybe you can get a few pointer from that thread. If im not wrong it should be under "Hand's On" try finding for it.

[doubl3mint]

oh ok bro thanks for the tip! the bike is with my regular mech now, we're trying to determine if the bike is worth saving first, haha

[liquidy]

i thnking of rebuilding my ride as well. perhaps we could share some pointers. like what manuals and what equipment.

[Pandoras Kitten 3]

I deliberately got a near-scrap bike for the shop to rebuild and I knew which shop could do a proper rebuild.

 

So far my grossly overpriced 8 yr old 4 times owned Phantom (2.6k machine price w/ chrome package excluding insurance) is doing very well, performing and handling significantly better than similar models on the road.

 

As for doing it myself, well, that's why I want this bike to last 10 years. I'm learning the simple stuff first as being a born and bred Singaporean, I have no idea how a garage works much less know what is a torque wrench

[doubl3mint]

haha, sounds good! was it a full rebuild? and which shop was it, realised you left the name out

[doubl3mint]

i thnking of rebuilding my ride as well. perhaps we could share some pointers. like what manuals and what equipment.

 

hmm which bike is that? maybe can pm me, we discuss from there =)

[doubl3mint]

sorry double post

[ulysses_sc]

Sounds like an interesting project. I would think regular hunting on ebay will be required. The 1100 was a beast back then, and is very popular in the US for stunt riders and drag racers.

 

I'd suggest buy a workshop manual, then start from there. Stare at it long and hard, and have a clear mental picture what you want to do. Else you will end up with an unfinished project with parts scattered all over the place and an increasing bill if send to bike shop.

 

Keep us posted on the progress!

[Pandoras Kitten 3]

Oh lol later post about them too much become accidental advertising. I realise not all people are fans of certain bike shops (or agents) thats why I sometimes omit the names.

 

This shop is Motorpoint at Jalan Mas Puteh (just across the AYE from Clementi central). I don't know how they do it but both my bikes are bought from there and their engines are not only surprisingly powerful and efficient, but very reliable as well.

 

When they take in bikes for resale I notice they go over them with a fine-toothed comb and re-presented to new owners in a totally different and much superior condition.

 

The Phantom I spotted there was totally in pieces (just a frame) and I sort of knew that's the bike I wanted. Waited about 2 weeks for them to do up the bike (lots of new and re-chromed parts included when I complained about the usual corrosion).

 

I wasn't there to supervise them (busy @ work and mobility compromised w/o bike) but looks like they did a good job. It's the only Phantom in the world that can give 45km/l fuel economy and handle like a sportsbike. (I tried other Phantoms over the months and I more or less went wtf. Cornering very scary. Mine rolls into turns like a fighter plane and is perfectly stable.)

 

My late father was also a big fan of the shop. His CB250 seriously sounds like it has a turbine engine, better pickup than my 125Z some more. His Intruder 400 is simply divine. Others just don't come close!

[swiftee]

i have seen quite a few bikes being rebuilt from scratch by my friends

for me i only tried partial rebuild before, my pocket not so deep to be able to do a full rebuild yet

 

rebuild is nt for the faint hearted, you would need quite a bit of tools and space and a convenient place to put your half-finished bike while you are not working on it, also some open air area to do washing and painting, etc

 

most of e bikes tt ppl rebuild themselves are small simple bikes, e.g. some 2 strokers, 2b bikes etc.

for class 2 sportsbikes like the one you mention, it might be quite complicated to rebuild, i suggest you get a bike shop to do it.

maybe u can try racewerks

parts you can get from all the normal parts shops, e.g. eversuccess for suzuki i think

[doubl3mint]

Sounds like an interesting project. I would think regular hunting on ebay will be required. The 1100 was a beast back then, and is very popular in the US for stunt riders and drag racers.

 

I'd suggest buy a workshop manual, then start from there. Stare at it long and hard, and have a clear mental picture what you want to do. Else you will end up with an unfinished project with parts scattered all over the place and an increasing bill if send to bike shop.

 

Keep us posted on the progress!

 

Haha heard much about this bike, but I havent seen one of these in singapore, so when the opportunity came up I grabbed it, perhaps impulsively.

 

Cougar mentioned about the workshop manual too, and it seemed like a good idea, so i've been looking around for one of those. More for my mech than me though, living in a HDB flat doesnt provide enough space for me to dismantle anything major!

 

I'll definitely update if there's progress =)

 

Oh lol later post about them too much become accidental advertising. I realise not all people are fans of certain bike shops (or agents) thats why I sometimes omit the names.

 

This shop is Motorpoint at Jalan Mas Puteh (just across the AYE from Clementi central). I don't know how they do it but both my bikes are bought from there and their engines are not only surprisingly powerful and efficient, but very reliable as well.

 

When they take in bikes for resale I notice they go over them with a fine-toothed comb and re-presented to new owners in a totally different and much superior condition.

 

The Phantom I spotted there was totally in pieces (just a frame) and I sort of knew that's the bike I wanted. Waited about 2 weeks for them to do up the bike (lots of new and re-chromed parts included when I complained about the usual corrosion).

 

I wasn't there to supervise them (busy @ work and mobility compromised w/o bike) but looks like they did a good job. It's the only Phantom in the world that can give 45km/l fuel economy and handle like a sportsbike. (I tried other Phantoms over the months and I more or less went wtf. Cornering very scary. Mine rolls into turns like a fighter plane and is perfectly stable.)

 

My late father was also a big fan of the shop. His CB250 seriously sounds like it has a turbine engine, better pickup than my 125Z some more. His Intruder 400 is simply divine. Others just don't come close!

 

Yeah agreed about naming shops, but I guess everyone has different experiences. Even a good mech has off days sometimes, and it seems to be human nature to remember the bad experiences more. Sounds like a place I should check out though. I'll drop you a pm in a bit, regarding them, thanks!

 

i have seen quite a few bikes being rebuilt from scratch by my friends

for me i only tried partial rebuild before, my pocket not so deep to be able to do a full rebuild yet

 

rebuild is nt for the faint hearted, you would need quite a bit of tools and space and a convenient place to put your half-finished bike while you are not working on it, also some open air area to do washing and painting, etc

 

most of e bikes tt ppl rebuild themselves are small simple bikes, e.g. some 2 strokers, 2b bikes etc.

for class 2 sportsbikes like the one you mention, it might be quite complicated to rebuild, i suggest you get a bike shop to do it.

maybe u can try racewerks

parts you can get from all the normal parts shops, e.g. eversuccess for suzuki i think

 

yup you're right bro. my current bike for example, was stripped down and built back by a malay gentleman at his void deck. i paid a premium for it coz i knew how much work had gone into it.

 

i dont think i could do the same with this one though. actually the ideal situation is to find a reliable, friendly place that would be willing to undertake this project with me, even at a higher cost, at the same time sharing knowledge and basic skills on motorcycle maintenance.

 

of course, its a two way thing. i would be willing to do the more menial work like dispatch to collect parts, send components for outsourcing, cleaning and polishing, etc. hell, i would work part time for a month or two for free if i would be of any help.

 

if there's really no such place, i've found one of those self-storage warehouses in changi business park where the entrance is just by the road. seems like a good alternative to my own garage, haha. the availability of tools and equipment will be a headache though.

 

 

 

i think i'll take some pictures when i get the bike back. like HWZ'ners like to say, NPNT right?

 

oh and thanks for all the comments, it really does make me feel less alone in this!

[swiftee]

for class 2 sportsbikes like the one you mention, it might be quite complicated to rebuild, i suggest you get a bike shop to do it.

 

oops sorry i dunno y i said sportsbikes... for some reason i was thinking of gsxrs...

must be because its monday

 

anyway get a copy of the parts book for your bike too... it might be helpful to you

[ulysses_sc]

oops sorry i dunno y i said sportsbikes... for some reason i was thinking of gsxrs...

must be because its monday

 

anyway get a copy of the parts book for your bike too... it might be helpful to you

 

It is a GSXR1100WP. The Grandaddy of the Hayabusa. So, you are right!

[ulysses_sc]

Hi all

 

I've just taken possession of a '95 Gixxer 1100, and i'm thinking of doing a full rebuild, totally stripping the bike apart and putting it together again, changing whatever parts necessary in the process.

 

I was looking at some of the rebuilt 1100's online and its inspiring. But they're mostly ang moh's, and i'm unsure of any local resources available to me.

 

Do any of the bros here know of any shops that specialize in such projects, or have any contacts I can ring up (mechanics, parts, etc)?

 

Feeling somewhat clueless at this point, as this is my first such project. thanks in advance!

__________________________________________________________________________

 

in case anyone else needs it, here's the factory service manual!

 

http://www.scribd.com/doc/3098570/Suzuki-GSXR1100W-9398-Service-Manual

 

Rotary has a rebuilt GSXR1100WP for sale. Looks good. You may want to check with him what is involved in rebuilding your bike.

 

http://www.singaporebikes.com/forums/showthread.php/301459-GSXR-1100-WP-2.5K-Nett

[doubl3mint]

haha, that's the one i got! looks much better in the picture than in real life, frankly. but thats always the case right, haha.

 

nevertheless, its 15 years old and 2.5k so i didnt expect much. knew there was definitely some work to be done.

 

its also been sitting idle for a few months, and we all know what disuse does to stuff. gonna need some cleaning up and lubricating, hope i get some free time off my schedule soon!

 

 

yup swiftee you are actually right, it is a sportsbike. but i'm thinking of creating something like this.

(i also managed to find the parts catalogue! there's a shocking sheetload of parts, i hope most on my bike are still working, gosh)

 

 

creit to kleito from the gixxer forums. he rebuilt this

 

http://img822.imageshack.us/img822/7515/dsc6003v.th.jpg

 

 

into this

 

http://img805.imageshack.us/img805/6800/dsc06913.th.jpg

 

the link is in post #3, but registration is required to see his 23 page thread of the process with pictures. worth a read, its pure dedication man

Edited September 21, 2010 by doubl3mint

[ultimax]

What ever happened to that shop which used to conduct bike repair classes?

 

It was along Upper Serangoon Road.

 

That place would have been an ideal place for such a project. Good working environment, friendly mechanics who actually have diplomas in motorcycle repair!

 

Just can't remember the name ... and I don't think it's at Serangoon anymore. Used to be able to see it from the main road.

[doubl3mint]

bad news from the workshop today. went down to collect the bike but we discovered the carbs are leaking petrol.

 

in addition, white smoke from the exhaust which smells like engine oil and petrol. they're gonna try to fix the carb leak first, if its nothing major

total damage apparently could come to around 3k or so, with no guarantee if it will be problem-free, if major work is done on the engine and carbs.

 

contemplating exporting the bike if it comes to that. sigh.

Edited September 21, 2010 by doubl3mint

[Pandoras Kitten 3]

Oh dear, what caused all the critical gaskets and seals to fail at once?

[doubl3mint]

fact is i havent ridden this bike since i got it. it was on layup, and its been idle for a couple of months.

 

i dont have a habit of test riding bikes i'm about to buy due to insurance issues, but it sounded fine when i requested for it to be started. didnt run it for long though coz the oil was old and i didnt want to risk the internals.

 

after that i got it towed to my regular mech and asked him to give it the once through. and now i find myself pretty stuck, haha. definitely wont sell it to a fellow forumer, my bikes always come with my own QC seal.

[ulysses_sc]

definitely wont sell it to a fellow forumer, my bikes always come with my own QC seal.

 

I'll take it off ya for $1K! Lowballer alert!!

[S750WP]

I used to own the GSXR750WP the little brother of the massive GSXR1100WP. the engine is almost bullet proof and spares for this bike is easily available from Ebay USA. I still miss riding my GSXR750, its stable at high speed, due to its weight and the upright seating position, wont feel tired even riding it for hours, its more like a sports tourer rather than sportsbike.

 

I did most of the DIY on that bike myself except for the engine.

 

Generally you dont need to rebuilt the engine if it healthy, as this will cost a bomb to rebuilt.

 

Take care of the basic first.

Engine valve clearance

Fixed up any leaks from the engine

Carburetor cleaning

Spark plugs

Oil and oil filter

coolant

Air filter

Brakes Caliper and brake fluid, brake pad

Fork oil seal for leaks

Rear suspension for leaks

Tires, chains, sprocket

Wheel bearing, Steering cone bearing

Battery and the electricals

 

Btw I still have the Haynes manual for GSXR1100WP/GSXR750WP, and Suzuki agent Guan Hoe charge cheaply for valve clearance, carb cleaning and balancing.

Edited September 22, 2010 by S750WP

[S750WP]

bad news from the workshop today. went down to collect the bike but we discovered the carbs are leaking petrol.

 

in addition, white smoke from the exhaust which smells like engine oil and petrol. they're gonna try to fix the carb leak first, if its nothing major

total damage apparently could come to around 3k or so, with no guarantee if it will be problem-free, if major work is done on the engine and carbs.

 

contemplating exporting the bike if it comes to that. sigh.

 

If your engine is emitting white smoke, your engine block may have crack and coolant leaked into your combustion chamber. Monitor your coolant level and check your engine oil color if it has turn white.