1980 GS1000S Reluctant Rebuild

[John Kat]

David, I'm pretty sure everything will be just fine once you can clamp the airbox boots to the carbs before you pull the airbox up to bolt it to the frame. Lots of bikes I've worked on are the exact same distance from the frame bolts. The carbs just bend up a bit without the boots coming off.

I fully agree with AZR
Everything is normal, you just need to lift the airbox with the carbs attached and it will work fine.
Don't forget that the carbs are "hanging" without the airbox attached.

[Kiwi Canuck]

No Go Tonight

Well I had my Video Camera and Fire Extinguisher ready but could not get the starter button to work, had lights and dash was all lit up, when I was checking the fuse panel to see what voltages I was getting I noticed a hot fuse so I quickly disconnected the battery.
I checked all the fuses and the first two were 20 and 25 Amps no wonder I had a few melted wires when I got the bike.
It looks like something is shorting somewhere, so I'll leave it till tomorrow to look at it.

I'm knackered as I must have taken 2-3 hours just to finish getting the exhausts on tonight.
I put them on and took them off about 3 times until I realised that the header pipes for 1 and 4 are handed, who knew? and I had them on the wrong side and struggled for an hour trying to get the left pipe to fit on the right side. Once I got that sorted I still needed to get the bolts aligned at the back and they did not line up without a big of leverage.

Seems strange that they didn't just drop straight on as they supposedly came off this bike.
Would have been nice to hear the bike start after all that work, I did jump the starter solenoid wire to the battery and turned it over so that all works.

Tomorrow is a holiday here so hopefully I'll get a bit of time to look at the electrical issue then.

David, I'm pretty sure everything will be just fine once you can clamp the airbox boots to the carbs before you pull the airbox up to bolt it to the frame. Lots of bikes I've worked on are the exact same distance from the frame bolts. The carbs just bend up a bit without the boots coming off.

[Kiwi Canuck]

New pictures

Here are the pictures that show the misalignment of the carbs to the Air Box, the only conclusion I have come to is the intake boots have been replaced and are not the same as the original ones.
Cowboy, does not make a difference which side I put in first, the box is low by about 1/2" and the bolt holes will not line up.
When I lift the airbox to align the bolt holes the rear boots slip off, as the new band clamps are a little too big.
Not a big deal as long as the air filter box fits and I can bolt that down so it should hold everything together.

This picture is with the carbs in the neutral position, just where they sit.



Here the side view with the airbox in it's "correct" position.

[cowboyup3371]

WHat happens when you clamp the carbs to the airbox first then push up into the intake?

[Charlie G]

Nice to see your not in this project alone. I hope you give them encouragement to learn wreching techniques in nicer language than my step dad. In my day I was lucky to have a lawn mower with wheels, let alone a motor.

[Kiwi Canuck]

More help

John has been helping with a bit of wrenching as well.

Here he is helping with the exhaust install.



Now back to the real chores.

[Kiwi Canuck]

My helpers

Got some help in the garage today, Alexander helping with polishing the exhaust pipes.

[Kiwi Canuck]

Nice suggestion here, SV. Just checked, and whereas the right mount could be mistakingly installed backwards/rotated, it appears the left one can only go one way. Still wondering if carb-to-head boots have a right/wrong situation



Priceless

So I needed to remove the carbs because I forgot to install the starter motor bolts and I didn't feel like messing around with trying to install them with limited space, so out they came.
I have measured the cylinder intake boots 6 ways to Sunday and they are in fact symmetrical no different either way up.
SV good thought on the engine mounts, already thought of that but as the rear and lower mounts are fixed it's actually not possible to get it in wrong.

[Frank Z.]

A thought just occurred coming from this post.Are you SURE the front motor mounts are the right way around? Just might make a bit if a difference,not sure it will but might be worth a look.

Nice suggestion here, SV. Just checked, and whereas the right mount could be mistakingly installed backwards/rotated, it appears the left one can only go one way. Still wondering if carb-to-head boots have a right/wrong situation

"As I?m trying to get everything ready to fire her up, any advice on pre-startup procedures before I push the button."

fire extinguisher....and a video camera.

Priceless

"As I?m trying to get everything ready to fire her up, any advice on pre-startup procedures before I push the button."

fire extinguisher....and a video camera.

Stunning rebuild, Kiwi. Good luck with the fire up.
Spoke with a seasoned UJM mechanic last night over a few barley pops, and mentioned the air cleaner bolt-up problem. His (smart-azz) comment: shim the motor 2? forward

btw: those Pings look a bit neglected...

A thought just occurred coming from this post.Are you SURE the front motor mounts are the right way around? Just might make a bit if a difference,not sure it will but might be worth a look.

[Kiwi Canuck]

Thanks

Stunning rebuild, Kiwi. Good luck with the fire up.
Spoke with a seasoned UJM mechanic last night over a few barley pops, and mentioned the air cleaner bolt-up problem. His (smart-azz) comment: shim the motor 2? forward

btw: those Pings look a bit neglected...

Thanks for the kind comments Frank, and yes those fine golf clubs haven't seen much use this year, not sure why.

[Kiwi Canuck]

New Parts

Finally got my last shipment of parts needed (ha ha) I know I will always need something else but it feels like I'm close to having everything I need.

Ordered new rear brake pads from Suzuki, not sure why as I could have got aftermarket ones for 1/2 the price, maybe they are twice as good.

Also got a few other misc. goodies needed, including a new gasket and 3 new acorn nuts for the oil filter.



Look what I discovered when I went to install the filter cover, it didn't feel quite right when I tightened it up.



Two very thin washers on the bottom stud, very strange, I'm not sure how it sealed with it like that. Just another example of fine workmanship from the PO.

[Frank Z.]

Stunning rebuild, Kiwi. Good luck with the fire up.
Spoke with a seasoned UJM mechanic last night over a few barley pops, and mentioned the air cleaner bolt-up problem. His (smart-azz) comment: shim the motor 2? forward

btw: those Pings look a bit neglected...