Accidental 100GS rebuild

SeanW · Aug 22, 2011

Got a bit carried away during a few days off work last week - instead of refitting the 100GS's swingarm with its new bearings and refurbed driveshaft, and getting the bike back on the road for the end of summer, I decided I might as well take a few more bits off to clean up / repaint / refinish / replace leaking seals/gaskets etc.

One thing led to another. It's now just a large heap of parts.

Thinking I might use this thread to chart its gradual resurrection, on a lowish budget / DIY basis where ever possible.

Would that be something vaguely interesting for you airhead tossers here to follow?

fayeslane · Aug 22, 2011

Yeah...........vaguely

MattW · Aug 22, 2011

My favourite sort of thread - bring it on :thumb2

MickDB1 · Aug 22, 2011

I like these threads :thumb2

I think they will help you remember what you have done as well :rob

Good selling point maybe :thumb2

Kenny · Aug 22, 2011

Yup, bring the rebuild on :bounce1

very stimulating these threads, in fact, I've just opened a brand new tube of Solvol Autosol :thumb2

BigyellowGS · Aug 22, 2011

always good to have a rebuild to follow :thumb2

(RIP) pastyman · Aug 22, 2011

Yup, I took a side panel off to repair a crack and finished up with a much bigger rebuild, Do it ... we all like a good look at what someone else is doing

SeanW · Aug 23, 2011

Ok, some photos follow which may explain my compulsion to dismantle...

However, I'm not aiming for a concours rebuild - it needs to remain tatty enough that I won't be put off riding it.

SeanW · Aug 23, 2011

reduced to component lumps...

SeanW · Aug 23, 2011

mmm, rusty

SeanW · Aug 23, 2011

badly corroded hagon shock. hoping you can get these rebuilt. chrome is on way out at bottom of shaft

SeanW · Aug 23, 2011

right side cylinder has allegedly had helicoiled studs

but hard to tell if oil leak at base was prior to this (the previous owner was not a fan of cleaning) or has appeared subsequently

SeanW · Aug 23, 2011

cascade of oil on left side doesnt; come from pressure sensor (?) as it apperas but actually from leaking breather at top of engine - small amounts over a long period have come out of the drain hole and worked their way down and backward...

SeanW · Aug 23, 2011

final pic shows dampness in clutch housing, but I believe this is due to the left side leak.

Might pull clutch off to be sure rear crank oil seal is Ok though, as front one certainly is not...

SeanW · Aug 23, 2011

This is actually an "after" pic of the rear wheel. After a lot of degreaser, brake cleaner and scrubbing (and four new spokes and a new tyre).

Disappointing, but am resisting the temptation to start thinking about getting the thing relaced and the rim polished...

pete.keys · Aug 23, 2011

SeanW said:
mmm, rusty

Hi Sean - good work!!

I was really surprised how cheap it was to get the frame blasted and powder coated. Just £100 for frame , rear subframe, centre stand, swingarm, panier racks and other bits and bobs.... really rusty frame came up like new!!

slowkitty · Aug 24, 2011

SeanW said:
This is actually an "after" pic of the rear wheel. After a lot of degreaser, brake cleaner and scrubbing (and four new spokes and a new tyre).

Disappointing, but am resisting the temptation to start thinking about getting the thing relaced and the rim polished...

Hiya. Autosol polish and loads of elbow grease should work. Use autosol soaked strips of rags on the spokes in a sawing motion. If you are really disturbed by it, strip down the wheel and polish it, but you will then have to get these cross-laced ones rebuilt professionally to true it accurately.

Crapaud · Aug 24, 2011

However long you think it going to take and however much you think it is going to cost, I suggest you double or even treble your original estimates.

fayeslane · Aug 24, 2011

Crapaud said:
However long you think it going to take and however much you think it is going to cost, I suggest you double or even treble your original estimates.

Yep

SeanW · Aug 24, 2011

Crapaud said:
However long you think it going to take and however much you think it is going to cost, I suggest you double or even treble your original estimates.

As a project manager, I am more than familiar with this concept.

However, having had a chance to inspect most bits in a lot more detail now, I'm feeling fairly confident that most of the bike's "real" issues are fairly superficial and therefore cheaply and easily fixed. Or, like the dent in the tank, they can be fixed at a later date if it comes down to it. It's the stuff that needs a lot of disassembly to fix that I'm going to concentrate on.

Timescale and cost will therefore more or less be in direct proportion to how shiny (or not) I'm willing to have it end up. And at the moment, my sights aren't that high.

Can I ask where the £100 blast and powder coating was done?

Accidental 100GS rebuild

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