Progress!!! 1978 GS1000E Restoration/Performance Rebuild

[limeex2]

To quote my twenty something y/o son. Dude this is sick!

[philosopheriam]

To quote my twenty something y/o son. Dude this is sick!

Thanks homes :-)

[dorkburger]

Actually, I have been behaving myself - supplements are for AFTER engine assembly time, not during... I want this engine to actually run

From experience......dont drink (wine) and wrench.

[Battleship62]

Hey!! Long time, no hear from!! LOL! How is your engine holding up?
Ray.

I will be reintroducing this project bike again as it goes into is final phase of mods which is just a few odds and ends. Additionally, last fall, the bike and I got tangled up with a box truck who's driver was decided to test his emergency stop maneuver in front of me. I missed the truck but laid the bike down off the road (in the dirt) doing ~25MPH. I got the bike mostly repaired over the winter but she's not quite done for show and tell. As for the engine, its rock solid and aside from scraping up the stator cover, survived unscathed.

[philosopheriam]

(really huge grin while posting these... very excited to pick everything up on Monday)

Frame Powdercoating
IMG_1195 by Anthony Monteleone, on Flickr

IMG_1193 by Anthony Monteleone, on Flickr

IMG_1192 by Anthony Monteleone, on Flickr

IMG_1194 by Anthony Monteleone, on Flickr

IMG_1187 by Anthony Monteleone, on Flickr

IMG_1186 by Anthony Monteleone, on Flickr

[philosopheriam]

Swingarm and Center Stand Powdercoating
IMG_1190 by Anthony Monteleone, on Flickr

IMG_1191 by Anthony Monteleone, on Flickr

IMG_1189 by Anthony Monteleone, on Flickr

[jsandidge]

Sure looks sweet!

[JTGS850GL]

Just curious, how much did it cost to have the frame, swing arm and center stand powder coated? I understand if you don't want to say. Just trying to get an idea of the cost of my next project.

[philosopheriam]

Prices were $275 frame, $65 swing arm, $40 kickstand, and $10x4 bearing and bushing removal.... In total, $420.

There was a slight delay in completing the work so I received a bit of a discount off this price.

[nvr2old]

Those parts look amazing. I didn't see the swing arm mod anywhere in the thread. Did you do that yourself? Beautiful parts. Can't wait to see it all come together.

[philosopheriam]

Those parts look amazing. I didn't see the swing arm mod anywhere in the thread. Did you do that yourself? Beautiful parts. Can't wait to see it all come together.

Actually, I have another thread in the forum that details the modifications done to the frame - I had Framecrafters in Union, IL do all of the work. If you search for "Framecrafters" you will probably find it :-)

[philosopheriam]

Here's the Framecrafters link;

http://www.thegsresources.com/_forum...!!!!&highlight=

[philosopheriam]

Folks,

Sorry for the lag in updates - I'm a heavy equipment mechanic, and this time of year is "go" time. Been working weekends and long hours and attending training classes during the day (I work midnights). Nonetheless, I've been trying to squeeze as much progress in to my free time as possible.

Final test-fit of trans gears and clutch basket (modified 1100 basket compliments of rapidray)
IMG_1202 by Anthony Monteleone, on Flickr
IMG_1201 by Anthony Monteleone, on Flickr

Checking piston-to-valve clearance using the professional's choice of clay..... Play-doh
IMG_1203 by Anthony Monteleone, on Flickr
IMG_1205 by Anthony Monteleone, on Flickr
IMG_1204 by Anthony Monteleone, on Flickr

After doing the clearance checks, we discovered a *very* small amount of interference between the outside edge of the intake valve and the half-moon relief that is cut into the top of the piston (these are Wiseco 1100 big bore pistons). This would make sense, as I am running APE oversize valves, +2mm on the intake and +1mm on the exhaust.

To solve this, we removed the exhaust and intake valves from #1 on the head and then reinstalled the head/cylinders with a piston (1-2-3-4, respectively) inserted into the #1 cylinder. We wrapped a feeler gauge around the piston to simulate the gap taken up by the rings. Then, with the engine at TDC, we used a transfer punch that had the same diameter as the valve stems and dimpled the top of each piston by inserting the punch down the valve guide until it contacted the piston on both exhaust and intake sides. This will give us a point from which to zero the milling machine when we enlarge the piston reliefs.

Once my buddy is done cutting the pistons, I will post more pictures of the follow-up assembly. Thanks for your indulgence

[philosopheriam]

NOTE:

For anyone interested in using an shaved 1100 basket in a GS1000, the edge of the original GS1000 plate carrier will have to be turned down on a lathe until it matches the diameter of the 1100 steel drive plate. Otherwise, the GS1000 plate carrier WILL NOT fir inside the 1100 basket - it's a smidge too big. Just an FYI.

[philosopheriam]

Just purchased these as well :-)

Mikuni RS34 flat-slide carbs
Mik_RS36-2005 by Anthony Monteleone, on Flickr

APE Pod filters
filters2 by Anthony Monteleone, on Flickr

Delkevic SS Exhaust
exhaust by Anthony Monteleone, on Flickr