1978 GS1000 Complete Engine Overhaul With Mods

[lecroy]

I looked in my boxs of GS junk and turned up nothing. I gave an engine an a set of cases away a few years back and I think these were in the mix.

 

[Hoomgar]

No worries. Thx anyway Lecroy.


So now, who can tell me what is wrong with my pictures of the gauges posted yesterday? I already got the answer about if they go on top or bottom, but did any of you notice that I had the rubber gromets in upside down too!

I am such a monkey :lol: The wide part you see in the pics goes on the bottom. Well the good news is I now have the gauges installed correctly


LOL!

I am finishing painting of the calipers and assorted other bits and have the new rubber parts on the way. With the extra week delay in the motor I have some much needed time to get her back together.

I spent tonight cleaning, sanding and painting and I took some time to bleed out both front and back systems until they run clean out the end of the hoses.

The electricals are in but I have another question. Is there a sure fire way to know how the wiring harness sits into all it's clamps or do you sort of just tug and pull as you hook things up and then button her down?

 

[wrench]

Mark your manual should show you were the harness goes 8)

 

[Hoomgar]

Mark your manual should show you were the harness goes 8)

It doesn't. I mean, I know where it runs and all. But how far forward and how far back? You know what I mean? I cleaned it good a year ago and it has been off the bike even longer so any marks from the clamps are gone. I guess I will just have to leave it loose until I get everything in and then button it down. I can't see any other way.

 

[wrench]

You'll figure it out buddy 8)

 

[first timer]

i started from the back and worked my way forward, get your self some little zip ties and use those to help postion the harness, cut them and move the harness then add new ones and so on. the harness will kinda work it's self out.

-ryan

 

[Hoomgar]

Thx Ryan. That's what I will try. As soon as I finish these brake calipers I am going to start remounting signal lights, brake light switch, etc...

As soon as I do that I can start reconnecting the ends and work it back up through. That's kind of what I was thinking I would need to do.

 

[Guest]

Are you getting excited yet??

 

[Hoomgar]

Are you getting excited yet??

It's killing me buddy I am going to get more parts tonight (sprockets and Dyna coils) and keep plugging away on assembly. last night I was working on the rear end, fenders, associated hardware, etc...

Everything is getting a quick cleaning and some paint where needed at this point. I am basically cleaning and putting it back together.

The whole paint job thing is bummin me out though. I really wanted to paint it yet. But I don't see it happening :|

 

[Guest]

paint has gone to the back burner for me too. I just want it gunning great first and all the mods done then I am painting

 

[Hoomgar]

paint has gone to the back burner for me too. I just want it gunning great first and all the mods done then I am painting

Maybe I will just except that it will be an ugly duckling this year and enjoy it. Then I can paint it next winter.

Next winter already has a Turbo bike project though :twisted:

 

[Hoomgar]

I picked up my rear sprocket and coils last night. The rear sprocket is a 41 tooth but I ordered stock 42T. But you know what? That is only one tooth and it is in the rear so I am going to use it. It will make my gears only just a little bit taller and I wanted that anyway.

I posted a question in the tech section about wiring the coils. I need help.

http://www.thegsresources.com/_forum/viewtopic.php?p=311024#311024

 

[Hoomgar]

I am really hurtin here guys. Need help. Anyone, Earl, Dink, katman, anyone at all? I am getting desparate. Running out of time and I simply cannot figure it out.

Please help!

http://www.thegsresources.com/_forum/viewtopic.php?p=311687#311687

 

[Hoomgar]

Some of you guys really rock. I got these great scans from Lynn and Sandy is going to get some live shots for me as well. I am still wanting both because some of the things in this picture posted below are not like my bike and I am sure it is because there are differences in the models.

Rock on!

-

 

[Hoomgar]

Mark, don't forget to install the brake line guide with the right side bracket bolt.

Keith, at first I didn't see what you meant but I found it when reinstalling the front master cylinder

Thx!

 

[crag antler]

Any in-progress photos Mark? Even sans motor.
Be interesting to see how your progress is going. Don't fret. It ain't completetly warm out yet. :wink: :? :roll:

 

[Hoomgar]

Fair enough. John and you both asked now so here they are

I wasn't posting any yet because there really isn't much to see unless you
have done one from frame up before and know what to look for. I guess
the best way is to compare.

Here is a shot of it from a year ago. As of early
last week it still looked exactly like this:

Now as of tonight it looks like this:

That's all for now. But I am working on it. I guess I am a bit slow :lol:

 

[lecroy]

Hey, its looking like a bike. Where is that engine???

I finally am starting to work on mine. I had all the parts in hand, picked up the wheels today. Cut the chain and started to put it all back together. I just started to put the new chain on and realized that they had shipped me 520 sprockets and 530 chain. The teeth and links are correct. JT, who makes the sprockets, shows the 520 being used on the 750. They sure are baby small compared to the 530. So, the whole thing has to come back apart. Will be interesting to see if I get some free 750 sprockets out of this.

If your needing chain, I am changing to EK. It will be interesting to see how it holds up.

I was surprized by the little amount of wear on the front sprocket. On the GS with the 630 chain, I have pulled the teeth way apart. These look in great condition by comparison.

 

[Hoomgar]

I am going with the 630 stock chain and sprockets now lecroy.
I wont be doing the conversion. I just see no need. I have the new
sprockets and chain in already.

Tonight I got the wiring harness sorted and the tail piece and tail light on.
I also got all the signal lamps in and the lenses on.

The tail piece, tail lense and blinker lenses are all brand new OEM NOS
parts I aquired a while ago for this project along with some other goodies
including the new NOS seat. None of them have been out of the box
before. It feels good to put some new parts on it

I also cleaned all the engine mount hardware and put all the mount
brackets back on. I should have it close to wrapped up by Wednesday
night.

I scheduled with Joe today to take this in then Thursday morning so we
can put the engine in. I traded my Good Friday for the day off. I sure
hope he doesn't blow me off until next week again :roll:

 

[marcovandevelde]

Wow man, most definitely a great project.
This will be the newest looking bike on this site!

And when I looked at your pictures I noticed that you like to play some music too while working on the bike. :lol:

Greetz, Marco.