Category Archives: Tools and tips

More work on the GSXR1100 clutch

With the weather finally becoming a bit warmer it was time to get stuck-in to some more jobs in the garage. I ordered a replacement clutch hub for my GSXR1100 before Christmas, and with bike on the lift I can get started.

I had previously replaced the steel plates, which looked very warn, and possibly part of my clutch issues where the plates were sticking. I’d also previously tried to dress the wear damaged on the clutch hub splines, but having ridden the bike again it was clear I needed a new hub.

Suzuki gsxr 1100

£870.00 (23 Bids)
End Date: Monday May-20-2019 18:05:23 BST
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The process takes roughly 90 minutes to complete, plus a bit more time if you also need to remove the bottom fairing. I prefer to remove all the clutch plates before removing the hub, so you’ll need a magnet to make your life easier. The clutch hub minus the plates is also easier to handle, and you are less likely to dislodge the clutch basket when removing the hub.

You’ll also need to replace the crush spacer and washer when refitting the hub. The 50 to 70 NM required torque for the hub spacer nut is fairly low when compared to later models, some make double sure washer is folded around the nut to prevent any movement.

I’ve not had a chance to ride since reassembly, maybe I’ll have time for a quick spin before I start on the suspension linkage.

Ride safe,

Al

TuneECU free diagnostics tool

Making the most of your Tune ECU

Update! Android versions now available for download via Google Playstore

If you own a motorcycle which has fuel injection installed, you will probably have an Engine Control Unit (ECU) installed which controls and monitors various aspects of your motorcycle.

In the past the only way to analyse your ECU was to visit the local dealer who had access to expensive diagnostic tools, such as the Texa Axone.

Texa Axone 5 Nano S Car & LCV Diagnostic Package

£2,700.00
End Date: Wednesday May-22-2019 17:29:33 BST
Buy It Now for only: £2,700.00
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Due to the rise of open source software development and on-line owners forums, you can now access your engine ECU to diagnose and review your ECU by downloading free software.

USB cable for Triumph Motorcycles TuneECU FTDI FT232RL Chip OBD II KTM Tune ECU

£14.95
End Date: Saturday May-25-2019 14:52:15 BST
Buy It Now for only: £14.95
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I started to experience running problems with my 2003 Aprilia RST, and found the options to accurately review fault codes via the motorcycle dashboard are limited and clumsy.

If you experience intermittent faults it was virtually impossible to diagnose because the dashboard would only display the latest fault code after turning off the ignition, removing the seat to connect up the diagnostic circuit, then turning of the ignition.

If the fault didn’t reappear when the ignition was turned on you would be back to square one – very frustrating! After lots of searching around the internet I found a website called TuneECU which provided free software to analyse your ECU through a custom made cable. The website also contains information regarding how to make the cable for your specific bike, alternatively you can buy the correct cable from most online auction sites (I got mine from ebay.co.uk).

Before you get started with TuneECU you should be aware that you can cause some serious damage to your ECU (and your bike) if you don’t know what your are doing, so please read all the tutorial information on the website and watch the various YouTube videos.

I found TuneECU to invaluable for diagnosing problems, rather than trying to work through the fault tree in a maintenance manual. I hope you enjoyed the article, and find it useful for your modern barn finds!

Ride safe,

Al (Barnfindmotorcycle.com)

Suzuki GSXR1100 clutch slave cylinder rebuild

Suzuki GSXR1100 clutch slave cylinder rebuild

When I removed the sprocket cover and clutch slave cylinder, it was clear the slave cylinder was in poor condition. The outer surface rim was damaged, and the inner cylinder wall and piston were worn beyond repair.

GSX R GSXR 1100 1300 GSF 1200 VS 1400 VL 1500 CLUTCH MASTER CYLINDER REPAIR KIT

£24.10
End Date: Thursday Jun-6-2019 14:57:53 BST
Buy It Now for only: £24.10
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Genuine Suzuki Clutch Master Cylinder Repair Kit GSXR750 F G H GSXR1100

£43.05
End Date: Wednesday Jun-12-2019 9:05:46 BST
Buy It Now for only: £43.05
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I ordered a complete replacement clutch slave cylinder, and also painted the sprocket cover whilst removed from the bike. Hopefully I’ll have some time this weekend to reinstall, and hopefully resolve my clutch problems!

Ride safe,

Al (barnfindmotorcycle.com)

Suzuki GSXR1100 master cylinder rebuild

Leaking Suzuki GSXR1100 master cylinder and rebuild

I’ve been having a few problems with my GSXR1100 clutch recently, where when the clutch lever is fully pulled-in it still feels like the gear wants to engage when the engine is revved. I tried bleeding the system a few times but didn’t see any difference, so looking at the master cylinder was the next logical step. The master cylinder dust seal showed signs of leaking, so I decided to undertake a complete overhaul.

The first task was to strip and clean everything in the ultrasonic clear before installing the repair kit. Hopefully this will resolve this resolve the problem, but also expecting to service the slave cylinder, which hasn’t been off the bike for a long time.

GSX R GSXR 1100 1300 GSF 1200 VS 1400 VL 1500 CLUTCH MASTER CYLINDER REPAIR KIT

£24.10
End Date: Thursday Jun-6-2019 14:57:53 BST
Buy It Now for only: £24.10
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Genuine Suzuki Clutch Master Cylinder Repair Kit GSXR750 F G H GSXR1100

£43.05
End Date: Wednesday Jun-12-2019 9:05:46 BST
Buy It Now for only: £43.05
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Another job on the list!

Ride safe,

Al (Barnfindmotorcycle.com)

Aprilia RSV rear suspension service

Servicing Aprilia RSVR rear suspension

I’d been putting off this job for a while, and finally managed to make a start on servicing the rear suspension last month. I purchased a complete linkage servicing kit from Aprilia Performance, which includes replacement bearings, linkage pins and dust seals for the “dog bone” linkage and centre link on the swingarm.

Whilst the rear linkage was removed I also removed the rear shock absorber, which I sent to MCT Suspension to be serviced and rebuilt. The rear shock has now been returned and ready for installation.

I’ve taken my time to ensure the linkage bearings have been correctly installed within the “dog bone” and centre link on the swingarm.

The “dog bone” bearings were fairly easy to install but the swingarm centre link bearings were more challenging. I made several attempts to install the centre link bearings, but each time I tried one or both of the bearings wouldn’t line-up correctly and the linkage pin would install correctly.

I eventually had to give the bearing recess a good clean with a polishing mop attached to my Dremel flexible drive. After giving bearing recess a thorough clean with the polishing mop the new bearings were a lot easier to seat correctly, and linkage pin moved freely when pushed through the new bearings. If you don’t have a Dremel in the garage, I’d suggest getting one with the flexible drive attachment which makes the fiddly jobs a lot easier.

TERRATEK 234PC ROTARY MULTI TOOL DREMEL COMPATIBLE ACCESSORIES MINI DRILL HOBBY

£27.99
End Date: Thursday Jun-13-2019 23:16:32 BST
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Hopefully I’ll get around to finishing the RSV rear suspension rebuild over the next few weeks, then I’ll need to look at the rear wheel bearings and sprocket carrier bearing. A never ending list of jobs!

Ride safe,

Al