gs1000 reassembly

[80GS750]

ok guys, i just ordered my complete gasket set online.

my engine is pretty much disassembled right now...

clutch and all electrical is removed, cylinders and pistons off.

where do i start? the mech that tore it all apart did a great job labeling everything and keeping it all in bags, thank god.

he said everything looked fine, and from what i have seen it all looks good. i got 98% of the carbon off of the pistons and they seem to be in good shape. the rings are still on them.

can i just put them back on and reassemble my top end? whats wrong with using the old rings? will it hurt anything?

never had an engine apart this far, so i kinda need to be spoon fed for now.

its a 78 gs1000 2 valve.

i have the manual so i wont need detailed directions, just a little guidance on what to do when....

[Steve]

If you have it that far apart, it is false economy to not change the rings and hone the cylinders. When you take the rings off, break one of them (very carefully) and use it to clean out the grooves on the pistons.


.

[mark]

It is a must to use NEW circlips when you put your pistons on the connecting rods. Do NOT use the old ones. I would get new wrist pins as well, but that's just me.......$5.00 a piece.

Make sure your gasket surfaces where your block meets the case and your head meets the block are cleaned well. Like above post says, honing and new rings should be installed.

[80GS750]

ok, so where can i get a hone? and also, what piston rings and clips do i need? i really have no clue where to start, so any links or specifics are greatly appreciated.... thanks guys....

[80GS750]

ok

http://www.bikebandit.com/partsbandit/showschematic.asp?dept_id=992089

clips are number 25, pins are 24. rings are 23.

looks like $30 per piston for rings, $8 a pin, and $.67 per clip.

does that sound right? wow

[80GS750]

cyclepartsnation is a little cheaper than that...

[80GS750]

i found the overbore kits... $400. i did a lot of searching and didnt see any other places than bikebandit and the other one...

are all those prices per piston?

thats gonna be like $45 a piston then?

wow. once again any info is greatly appreciated. thanks guys

[80GS750]

dont worry guys. i will have all engine mate surfaces clean and prepped for new gaskets... already replaced the head gasket on my 750, its working out great!!!

[mark]

Here's where I buy anything I can. Not always the cheapest but usually cheaper than Bike Bandit and they've gone the extra mile for me a couple of times. Get to talk with a real person too. Ask for Jeff at ext. 111

http://www.z1enterprises.com/

Some others:

http://crc2onlinecatalog.com/

http://www.alpha-sports.com/suzuki_parts.htm

http://flatoutmotorcycles.com/fiche_select.asp

Prices you quote are ballpark for pistons and rings. I went 1st oversized pistons and rings for my 850 at $65.00 a set (piston and rings) from Z1.

[80GS750]

sweet! thanks man

[bwringer]

I've used a Flex-hone in three GS850 rebuilds so far with excellent results every time. It takes a total of about a minute with the flex-hone in a low-speed cordless drill to get a beautiful crosshatch in all four bores.

You can get Flex-Hones here in various diameters:

http://goodson.com/

Low-tech, works great, nearly impossible to screw up. Just keep the drill moving vertically at all times and only stop and start it when it's clear of the cylinder. Keep everything soaked in engine oil while you're honing (yes it makes a mess) and make sure the block is scrubbed squeaky-clean afterwards -- you don't want that abrasive getting into your engine. Wipe the bores with engine oil immediately to keep them from rusting.