The tossed 78 GS1000 rebuild thread.

haha on that third pic it looks like your car has a spoked wheel

[IanC]

Made a bit of progress. Got the new superbike bar, all the gaskets, random nuts, tach gear, rear brake light switch among other things in from bikebandit. Took 15 days to get the order!

New Progressive spring, got the new to me forks apart and discovered they had Progressive springs already. Oh well dad wanted a set anyway.


The tires on the wheels I got are brand new! Knobbies in the middle still.


Motor buttoned up.


Progress...


Not much clearance between the brake line and the cluster.

Glad to see the new parts.

Ian,

I'm glad to see the parts showed up and happy they look in good shape. To answer your question about the left side lower fork leg caliper mounts: No, I'm pretty sure the left leg caliper mounting points are the same. Easy to check..just compare and measure between your old left leg and the new one. You should be fine once you assemble a new right fork leg using a good fork stanchion and right slider with caliper mounts. (As a bonus, we should be one good fork tube away from a good spare set of forks which would be a nice sort of spare part to have stashed away.)

If you're ordering new fork springs order a set for me too. I think this summer I'll work on my Suzy's suspension now that we should have the carbs worked out. I have that JMC braced swing arm to mount and with better shocks in the rear and fresh fork oil and better springs up front that should give Suzy as much of a handling boost as I want to take on this summer.

I don't want to get too involved with the GS-S or Bimmer because I really want to get started on the Gamma restoration.

I worked on the Bandit today and changed the rear disc and brake pads, replaced slightly trashed old instruments with eBay treasures (I had to swap out the mph speedo to keep the kph one.), fabricated a mount for the remote reservoir for the GSXR1100 shock I installed (another eBay treasure) and changed the oil and cleaned like crazy while I had it apart. Your Mum is currently a bit miffed that her sink is full of filthy Suzuki parts. After 35 years you'd think she'd be used to it...

Speaking of GSXRs I was in a Red Baron shop in Yokohama yesterday with your Mum and she noticed a totally stock '86 GSXR-750 hiding in a crowd of used bikes for sale. It looked very good and only had a little less than 20,000 kms on it. It even still had the stock exhaust! Their asking price is 375000 yen which converts to 3955.50 at today's exchange rate. Hmmm....

BTW: Picked up your rear brake line at the Rough Road accessory store so you'll have all the parts for all the brake lines coming your way. Your Mum was scandalized at the prices. I mollified her by promising you'd reimburse her for the brake line set with an equivalent amount of knitting supplies. So head's up! Get ready to buy $200 worth of yarn in June or deal with a fired up maternal presence...

Dad

[IanC]

My bike was originally dual disc. I'll be using the lower from my original fork so I can mount the caliper. Thanks for the tire info.

Edit: Just re-read that, so the mounting point for the caliper on the left was different?

[Big T]

Two things

1. Widest tire you can put on that rim is a 120. 130's get all puffed up, leading to poor handling. You can get a wider rim that will accept a wider tire and go up to 150/160 width. But the rims won't match, as the GS 1000 rims have their own unique profile

2. You can't use single brake fork lowers for a dual brake set up, they're left side only. If you mount one on the right, the offset is wrong. Get some dual disc fork lowers and adapters

[IanC]

Hasn't been a lot to report lately. Been wet sanding my swingarm, wet sanding it some more and yet still wet sanding it some more. It's getting close to done. Mostly been waiting on parts.


Made up a new engine to battery ground cable as the old one was in sad shape. I'm working out a set-up to replace the underseat electrical connections with GM style weatherpack connectors. Like this:
!CEui!TwEWk~$(KGrHqJ,!hoE0hmc6BEvBNS)UCmYMQ~~_35.JPG
You can get them in a number of different connections and they are easy to custom pin. Best of all, as the name implies they are weather proof. So all those annoying bullet terminals will be replaced and any random ones left will be replaced with new.

New to me wire wheels to replace the mags. One was bent in the accident. I really like the looks of the wire wheels. Eventually these will have to be relaced as the wires are looking a little sad but that will be for another winter. Tires that came with them are practically new so I'll ride them out for a bit. The front wheel luckily came drilled/tapped for dual disc so that saves me a trip to the machine shop to have it done.

New forks. One of mine was bent. Since these came off the same single disc brake bike the wheels came off of I have to take one down and swap the fork leg out with my old one so I can mount dual discs. Which leads to another project, since I was already eventually planning on getting Progressive fork springs for it I might as well spring for them while I'm going to have a fork apart anyway. So Progressive front springs are on the way.

In a fit of wanting instant gratification I mounted the dual discs to see what they'd look like. I love the look of wire wheels with dual rotors. I plan on doing the cbr rotor/Kawi twin pot brake upgrade so I'll see if the funds are available before I button this all up. If not they'll come later.

Now I noticed that sliding the 1100 swingarm over the rear wheel gives me lots of spare room between the tire and swingarm. Does anyone know how wide a rear tire you can fit on these wheels and still clear the swinger? Also, the 1100 swingarm and the 1000 swingarm bearings use different part numbers in the microfiche. Does anyone know the difference? I know the 1000 one will work in the 1100 swinger but is the 1100 a better bearing?

[IanC]

No forks and wheels yet. I was assured they were in the mail as of yesterday so soon. To protect the frame I just taped up the sides of the frame and had a few people help slide everything down and get it lined up. There still ended up being a couple scratches that I need to touch up. The motor isn't bolted in completely yet. Not happy with a few fasteners and since the local hardware source doesn't have them I'll either order them from www.tastynuts.com (not a porn site ) or Fastenall. I hear rumors of a place in Knoxville that specializes in metric fasteners so I may try finding that.
The valves were mostly in spec. A couple were tight and replaced shims in those. Now to get Colin motivated to do his while it's waiting on parts.

Ian,

Love the shot of the coffee table. I think mix and match games make for an enjoyable evenings entertainment.

The headlight looks great too. I'm glad the headlight ears showed up. What about the forks and wheels?

I'm looking forward to seeing the engine in the frame. What did you pad the frame rails with while installing the motor?

Did you have to swap any shims when you checked the valve clearance?

Dad

[IanC]

My coffee table currently:



No, I'm not married. How could you tell? I did manage to save my original speedo face and internals. Dropped them into an 85mph shell I had. I didn't break the old shell open or mangle the trim ring, the crash did that. I don't know how my gauge face and insides survived but I'm not complaining.




New headlight and bucket. Sadly the trim ring has a ding. Oh well still got it fairly cheap.



New headlight mounting ears as one of mine was bent. Thanks dad!



1100 swinger I bought off of Eric_Banks32 here on the forums. Soon to be polished.

Also got my pan gasket in finally and the motor is back in the frame. I'll get a pic up soon.

[IanC]

Not much to update. While I've been waiting on parts I've been polishing bits and adjusted my valves. Thanks Steve for the handy spreadsheet, Cliff for his excellent site and dad for the loan of the tool and voice of experience. I snapped some pics of the new parts that have made it in but my camera batteries died so I'll try to remember to pick some up tomorrow.

Hi Mr. IanC,

Excellent progress. I recently went through a similar procedure rebuilding my bike after my crash. Luckily, my forks were not bent. I didn't take the engine out, but I took everything off except the engine in order to replace and repair the damage and perform other maintenance. I wish you luck and hope you have fun. I'm looking forward to your completed project. Nice work.


Thank you for your indulgence,

BassCliff

[IanC]

Thanks dad. Not really total black out. I think the lines will look good. There will be lot's of black, a bit of white and lots of shiny. Oh and a little blue. Planning on an Earl's cooler so I'll try and get blue fittings for that and they'll both be good contrast.

brake lines

Ian,

I boxed up your brake lines and will cart them over to the mailroom tomorrow. You should have them in a week or so. I hope the basic stainless braided lines and blue anodized parts such as the banjo fittings don't bother you. Had I known you were going for the total black out look I'd have gotten black lines and fittings. Sorry.

I like that the bike is starting to come back together and like the work you're doing, especially on the electrical panel. You sure are doing a nice job with our formerly orphan GS1000 refugee. This summer when we head north we should make it up to New York to show the former owner what became of his lost child. I think he'd like to see it.

Dad

[IanC]

Body parts on the frame to get an idea of looks.



Electronics panel all cleaned up and mounted.



Also re-wrapped the wiring harness and picked up a bunch of stainless bits and pieces. Gotta play the waiting game on parts now.

EDIT: I also found someone who can fix the tank so I'm pretty happy about that.

[IanC]

Quick update. Bought an 1100 swingarm so that'll be coming soon. Now to decide whether to paint, polish or leave it.

Frame drying.


Headlight mounting ear. The other is bent so either I have to find one of fix it.


Re-assembly starts soon!