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Old 01-15-2008, 12:13 PM   #1
Lornce OP
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Joined: Aug 2003
Location: Way Out There.
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My Garage Of Doom.

"Abandon hope, all bikes that enter here..."






Merged Thread Alert:

R100GSPD HPN-esque build!

R90/6 psuedo-restoration!

Buell S2 Thunderbolt restoration!

Buell S3 Thunderbolt touring prep!

Buell S1 Lightning Hooligan Redux!

It's all here under one roof... and more.

Cool stuff happens to a DR650, KLR 650, 640Adv, and Buell Ulysses, too.
But we can't talk about that here.







































































































Okay, I wasn't going to post anything here about it but I'm thinking you guys might prod me to keep going and get it finished before spring arrives.

Basically I'm planning to do a complete motor overhaul on the bike, top and bottom ends. It's been burning oil like crazy since an incident last summer that saw it wallow and drown in a deep mud hole. I'm doing the whole motor because I'm not convinced the damage was limited to the top end. Plus, the bike had a history of a bad oil pump early in it's life during the PO's watch and only the big ends and oil pump were replaced (I've never trusted the bottom end), so I'm doing the whole enchilada.

I've got a good '77 R100S bottom end laying around that I was hoping to use to form the basis of the rebuild/replacement engine. (Anyone know why the '92 timing case shouldn't bolt right up to the '77 block?) This will of course, permit use of the '92's ignition trigger and the post '81-type Andrews cam I've got laying around saying "use me in a cool bike".

Main bearings in the block and main and big end journals on the '77 crank are in top shape and since I've already got the crank out of the block I'll probably have it dynamically balanced. If the '77 block presents "issues" I'll just replace the '92's main brgns and use it.

I've been using this '92 with a modded high compression 1050cc '77 RS top end for the last couple of years and it works quite nicely in the mid range with the stock '92 cam. I'm likely going to stick with that top end combination along with the addition of the Andrews cam which is a high lift short duration type (I'll dig up the numbers as I'm able, unless one of you have them handy?) which should further increase the midrange and top end urge.

Carburation is handled by a pair of modded '77 vintage 40mm Bings. No need to change those as they work well to provide good power, reliable service and reasonable economy.

The plan is to continue using this bike as before for all around riding chores from commuting to quiet evenings in the country to weekend sprints with the sporty-boys to extended camping/touring adventures. ie: It has to remain reliable and maintain it's useful extended fuel range. fwiw, since the high cr 1050cc top end transplant it's gently ridden range went from 550kms to 700kms from it's 35 liter tank. A 25% improvement in economy and power. I was pleased with that result.

I'll post pics of the disassmbly as it begins (in a good friend's heated garage!) in a few days.

D'I miss anything?
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Old 01-15-2008, 12:54 PM   #2
Stagehand
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well, I'm in.
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Old 01-15-2008, 01:03 PM   #3
clevishook
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I'll be watching the progress of both you and stagehand. Great projects.
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Old 01-15-2008, 01:35 PM   #4
Eurobiker
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I'd send the trans off for bearing check, shimming, circlip mod and nylon shifter roller replacement with K-Bike steel one.
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Old 01-15-2008, 01:51 PM   #5
929bladerunner
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Nice one Lornce, I'm on the verge of buying an old GS that I will want to strip/re-build (mainly cosmetic). I'll br wathcing and learning.
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Old 01-15-2008, 02:59 PM   #6
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you said overhaul the top end- gonna go all the way?

how many miles on this thing, again?

Are you gonna touch anything aft of the tranny? (scope creep )
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Old 01-15-2008, 03:17 PM   #7
Lornce OP
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Yes, going all the way: Top and bottom end. Bike has 240k kms and was running just swell before the mud bog debacle. Though I always suspected the mains were a bit wonky (see earlier note re. oil pump).

I *might* pull the tranny apart and have a look at bearing clearances. We'll see how the time goes before spring arrives (mid to late March, weather permitting).

Cosmetics? Maybe I'll spread some red tremclad on the crashbars. They're now almost entirely orange with rust. Plus I'm getting a new-to-me-like-new Corbin. The old one gives me monkey butt when it rains.
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Old 01-15-2008, 03:25 PM   #8
datchew
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Ya Lornce! Another rebuild thread. That restore/rebuild section of advrider is getting closer everyday. I can almost taste it.


Welcome back from your long x-country ride on the /5. I enjoyed the thread.
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Old 01-15-2008, 06:47 PM   #9
moosehead
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Location: south of the checkerboard....Bruce Penninsula
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Don't forget a new and improved flag holder....



casa roberto awaits....
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Old 01-15-2008, 07:07 PM   #10
kahoon
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Quote:
Originally Posted by Lornce

[snip]

The plan is to continue using this bike as before for all around riding chores from commuting to quiet evenings in the country to weekend sprints with the sporty-boys to extended camping/touring adventures.

[...]
What about playing in the dirt with your poser buddies around Hockley, and the '08 P2D

Look forward to watching the rebuild I've been thoroughly enjoying of the 9fiddy rebuilds thread in the OC.
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Old 01-15-2008, 07:09 PM   #11
dfc
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Hey that bike looks familiar, and properly dirty. Is that a stock screen or did you get fooled by Gustafsson like I did?, Cant wait to hear how it works out, I plan to do push rod seals and rings this winter, much easier task.
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Old 01-15-2008, 07:49 PM   #12
Lornce OP
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Location: Way Out There.
Oddometer: 17,774
Yah know Moosehead, the flag would still be flying if I hadn't broken it while packing up my tent near Winnipeg just a few days from home. Even after that your duct tape mod held the base in place for nearly 11k miles! Red Green would be proud of you. Keep your stick on the ice!

Kahoon, straffing runs around Hockley Valley sideroads are high on the operational "to do" list once things are back together. I'll look forward to them. Though I might go lookin for a nice XR650R for the paris to Dacre!

Not sure about the screen, dfc, it was in the spare parts bag when I got the bike. It was wearing a big touring screen when I first brought it home. Anyone want that? It's still sitting in my basement...
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Old 01-15-2008, 08:09 PM   #13
DucatiPete
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how about a wash?

ya gonna bathe her before you operate?
hehe
luv these rennos...

pete
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Old 01-16-2008, 12:51 PM   #14
gonzomup
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Save a seat for me, guys!

I'm cutting my teeth on a "refurb" of my 1150GS (link in my sig' line), but I'm waiting for the day I can do a refurb/restore on an R80.

Bohdan
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Old 01-24-2008, 01:55 PM   #15
kahoon
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is the show starting soon??


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