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Old 02-14-2005, 07:08 PM   #1
gaspipe OP
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Location: Pickwick Lake, Tennessippi
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Building an ADVMoto R1100GS

I wasn't sure where to out this thread. Maybe JoMomma would be best

This will be ongoing, as long as I can remember to update it from time to time.

I figured out that I wanted something all but unoffered. I was looking for a bike that would handle and feel a lot like my 640 Adventure, but with twice the power. A bike that could plow down the two lane, as well as handle Baja, Mexico, Alaska, etc.

I thought I found that bike in the new KTM 950. As great of a bike as it is, it's not fuel injected and is expensive. And I'd feel awful tearing it up, and that will happen going into remote areas. I was just minutes from buying a 2004 S model.

Another idea bubbled back to the surface. What about Motozilla's 1150? Shaft drive, a smooth and tractable motor, used [cheap] parts availability, enough legs to cover many miles, and a lot less than 600lbs. Plus another ADV Rider I know has a low mile 1100 basketcase that would likely be a great donor.

I picked up the GS for a good price, 30k on the clock. The bike was disassembled because the rear main seal went, contaminating the clutch. The bike came with new seals, pressure plate, disk, bolts, diaphragm - all the new parts needed to redo it. But not installed. In fact, the bike was still disassembled.

We made a roller out of it, and it came home.



It looks worse than it is.

[to be continued]
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Old 02-14-2005, 07:31 PM   #2
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Once the bike got home, I pretty much had no time to work on it, and it got shoved off in the garage.

However, a quick inspection of what we have:
Good
30,360 miles
New Dunlop 604s
K&N filter
System bags
Cargo rack
New clutch parts

Bad
Bike sat for two years disassembled, and was filthy
Leaky head gaskets
Dented tank
Blown shocks
So I gave Motozilla a call. We spoke a few times to really figure out what I wanted to do, and we finally decided what it was I wanted. He ordered up the parts about three weeks ago.

Click here for Motozilla's Thread

Motozilla's bike:



The basic plan for my bike is a 21" Sun front rim, single disc KTM front brake, Motozilla's frame, 50mm USD forks & billet clamps, a race spec Bitubo rear damper, Pastrana bend bars and an IMO to replace the BMW gauge cluster and knock off some more weight.

Time to start working to prepare the bike for the transformation.

[to be continued]
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gaspipe screwed with this post 02-14-2005 at 07:57 PM Reason: fix error....
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Old 02-14-2005, 07:44 PM   #3
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You, sir, are a genius!

Sounds like you will wind up with the best of all worlds. Keep us posted.
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Old 02-14-2005, 07:55 PM   #4
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I finally got started this weekend. Not a lot of time, but I got started. I spent a couple hours cleaning the bike with a variety of things. I hate working on a filthy bike, and I hate filth from the outside getting INSIDE.

I drained all the fluids, magnetic plugs were clean, stuff looks good.



First order of business is removal of the ABS. There won't be any need for it any longer. And there will be a lot more room to operate. While I was scrubbing the filth from the rear wheel and hub, the ABS ring was removed from the hub.



Meanwhile some parts from Touratech showed up.



Elimination of the ABS is now complete. All the steel lines were removed, and new stainless lines will be run directly from the master cylinders. The rear caliper was cleaned up, new pads fitted and the pins relubed. I need to make a plug to seal the hole that the ABS sensor went through, or did BMW have one for the non ABS bikes?





Next step, remove the rear drive, swingarm and lube the pivots and splines. Then, I'll tackle the new clutch, and reassemble the rear end.

I should start getting some stuff in from Motozilla soon, and the thing will begin to take form.

Something to ponder: since I have to repair a dent in the fuel tank, what color should I reshoot it? Or should I Line-X it? Hmmm....
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gaspipe screwed with this post 02-14-2005 at 08:22 PM Reason: revised content
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Old 02-14-2005, 09:43 PM   #5
sherpa
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Quote:
Originally Posted by gaspipe
Elimination of the ABS is now complete. All the steel lines were removed, and new stainless lines will be run directly from the master cylinders. The rear caliper was cleaned up, new pads fitted and the pins relubed. I need to make a plug to seal the hole that the ABS sensor went through, or did BMW have one for the non ABS bikes? ....
The 3.0 final drives are available in a non ABS/non holed version.
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Old 02-14-2005, 10:11 PM   #6
ErrinV
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This is great Gaspipe. How much weight do you think you'll shave off by the time your done? Lookin' forward to following this thread.

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Old 02-14-2005, 10:26 PM   #7
Santa
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How much weight did ya save by pulling the ABS?
There is also a 3.2 final from the R850.
Got one, good mod.
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Old 02-15-2005, 02:53 AM   #8
AceRph
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Cool project gassie.

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Old 02-15-2005, 03:44 AM   #9
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Old 02-15-2005, 04:38 AM   #10
Steverino
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Wanna sell the ABS pump?
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Old 02-15-2005, 06:59 AM   #11
gaspipe OP
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Quote:
Originally Posted by Steverino
Wanna sell the ABS pump?
I've hacked part of the wiring harness to it. You're welcome to it if you want it, but you'll have to do some wire splicing.

All it will cost you is shipping.
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Old 02-15-2005, 07:06 AM   #12
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The ABS weighs quite a bit. Not just the unit/pump, but all the extra wiring (that I am painstakingly removing), hoses and junk adds somewhere around 25-30lbs, at least, if not more.

When I get the bike done, I'll weigh it. I'm guessing it should be somewhere under 500 lbs wet.

It'll be much 'skinnier'. That Telelever front end is no lightweight, and the factory exhaust weighs a ton. That I'm replacing with a Remus.

Other stuff that will get replaced include the gauge cluster and possibly the whole beak.
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Old 02-15-2005, 07:27 AM   #13
overlander
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Keep it going

Great plan! I'm watching and building a similar bike in my mind. Waiting for the cash to flow to do the deal on mine. Keep up the pictures!
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Old 02-15-2005, 07:48 AM   #14
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Old 02-15-2005, 07:55 AM   #15
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nice stuff!
I'm working on finding a donor too

Keep it coming!
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