Finally took the plunge.

[Matchless]

Dude... nice. I wish I had done that when my harness was off. Whats the benzine for, just to clean the insulation? And the hydroflouric acid got off any tarnish or corrosion from the wires and/or connectors?

J_C,
Benzine cleans off the old adhesive and grease/oil and the acid is for the brass terminal tarnish. You just have to remove it properly afterwards. Benzine does not harm plastic and there may other similar products out your way. Its a boring job, but impotant I think.

[Matchless]

Most overlooked, but very important item - the Airbox. Just completed it, sandblasted, powdercoated, fixed small diffusion box inside top for breather and sealed rubbers on side properly.
Fitted rubber boots to carbs correctly - always wondered why they were so difficult, they are also marked L or R and have a little mark showing the top. I never knew this before.
New stainless screws and ready to fit.

[Suzuki_Don]

Most overlooked, but very important item - the Airbox. Just completed it, sandblasted, powdercoated, fixed small diffusion box inside top for breather and sealed rubbers on side properly.
Fitted rubber boots to carbs correctly - always wondered why they were so difficult, they are also marked L or R and have a little mark showing the top. I never knew this before.
New stainless screws and ready to fit.

Great job Andre. Keep it going.
Cheers
Don

[Matchless]

Thanks for the encouragement Don, I am now past the point of no return and enjoying it!

[simon kuether]

I did a rebuild of a '79 GS1000S and did what you are doing.Keep going the way you have so far and you will end up with a "new" bike.I replaced ALL the bolts with stainless(cover bolts etc) or zinc plated high tensile for anything else(engine mounts,calliper mounts etc).I would also replace all the bullet connectors on your harness as well.They are no where as reliable as spade connectors.I had my wheels polished and repainted with a two pack and they came up beautiful.Every part I had ANY concerns with,I replaced with NEW.It might cost a bit but you will be rewarded with reliability.You are doing well so far.Keep up the high standard.Cheers,Simon.

[Matchless]

I did a rebuild of a '79 GS1000S and did what you are doing.Keep going the way you have so far and you will end up with a "new" bike.I replaced ALL the bolts with stainless(cover bolts etc) or zinc plated high tensile for anything else(engine mounts,calliper mounts etc).I would also replace all the bullet connectors on your harness as well.They are no where as reliable as spade connectors.I had my wheels polished and repainted with a two pack and they came up beautiful.Every part I had ANY concerns with,I replaced with NEW.It might cost a bit but you will be rewarded with reliability.You are doing well so far.Keep up the high standard.Cheers,Simon.

Simon,
Thanks for the reply. I am also replacing as many bolts as the eye can see with stainless steel. Also replacing all the bearings and seals. The wheels are my next 'larger' step. Once the rotors, bearings and tyres are off I will see how to go about it as they are of cosmetic importance as well.

[simon kuether]

Matchless old mate,be careful of stainless for any "structural" bolts as they are not very "tensile".Be sure to use antisieze on stainless as well or the threads can bind or grow into alloy.Just a slight smear will do.You are right about your wheels,if they are done well,they add to the appearance untold.I'll follow your progress with much interest as you seem to be going about things the same way that I do.That is , do it properly with as many new parts as possible.The long term benefits will be your reward.I can hop on my old girl knowing she will go and go and go,and I know she'll get me home.I'm off on a ride in 3 months that will see over 8000 km and the only prep I'll do is oil and filter.Cheers,Simon.

[Matchless]

Matchless old mate,be careful of stainless for any "structural" bolts as they are not very "tensile".Be sure to use antisieze on stainless as well or the threads can bind or grow into alloy.Just a slight smear will do.You are right about your wheels,if they are done well,they add to the appearance untold.I'll follow your progress with much interest as you seem to be going about things the same way that I do.That is , do it properly with as many new parts as possible.The long term benefits will be your reward.I can hop on my old girl knowing she will go and go and go,and I know she'll get me home.I'm off on a ride in 3 months that will see over 8000 km and the only prep I'll do is oil and filter.Cheers,Simon.

Thanks for the S/S mention. I am using #7 Stainless Steel bolts and only for those with the standard thread. The high tensile bolts, Suzuki #9 I am re-using where possible, but thanks for the heads up on that.
I have just ordered new fork seals although mine are still perfect. Thought I might as well replace while the forks are out.
I appreciate all input! And any tips are welcome.:-)

[simon kuether]

Matchless old mate,here's my old girl after completing what you have begun.Like I said,if you do it right,you'll have a faithful old girl that will give you no grief(except what all the old girls (both types)give us).As I was doing her up (she was a dirty girl when I found her),I replaced/refurbished EVERYTHING and now have a rare and reliable ride.Worth every cent I spent.Cheers,Simon.

[simon kuether]

Old mate the metal polisher did my wheels.Acid cleaned,painted and polished.Couldn't be happier.All up $400 for both wheels.Cheers,Simon.

[Johno]

Contacts in Australia

Simon,

I'm looking to do a similar refurbishment of my 1981 GS1000G.

I live in Sydney. Where do you suggest I can source replacement nuts and bolts. I have cleaned a number with rust but the plating has been damaged and they will rust again.

Your polishing also looks great.

Did you get it done in Brisbane?

Any advice would be welcome

[simon kuether]

Johno,I got all the bolts,stainless and zinc plated high tensile from the local"nut and bolt" dude.The polishing was done by a lad in Cairns.He did my carbs as well.Money well spent I reckon.Cheers,Simon.

[Johno]

Thanks Simon

Johno,I got all the bolts,stainless and zinc plated high tensile from the local"nut and bolt" dude.The polishing was done by a lad in Cairns.He did my carbs as well.Money well spent I reckon.Cheers,Simon.


Thanks Simon.

Much appreciated

[Matchless]

Matchless old mate,here's my old girl after completing what you have begun.Like I said,if you do it right,you'll have a faithful old girl that will give you no grief(except what all the old girls (both types)give us).As I was doing her up (she was a dirty girl when I found her),I replaced/refurbished EVERYTHING and now have a rare and reliable ride.Worth every cent I spent.Cheers,Simon.

Whaw, Simon, you actually did "everything". Its as smart as one can get it!! I do not think I will have mine like that soon. I will do the bolt on things later once the bike is up and running again and I need to do it over a longer period, otherwise my wife will not see this as a hobby!

Excellent!!

[Matchless]

Today finished the steering stem bearing replacement and reinstalled the revamped wiring harness as well as the coil relay and horn relay modifications as well as wiring for the 12 Volt assessory plug at the front.