1980 GS1000S Reluctant Rebuild

[Kiwi Canuck]

Thanks

Thanks

I got nuthin' ... other than to state I look forward to pictures of this completed project!! wow

Thanks for the comments, they really do help me stay motivated and you think you're looking forward to seeing pictures of this thing completed, ME TOO!

I love working on this project when things are going well, but I've had a few moments when I just want it done, seems I'm always waiting on something to arrive so I can finish the next piece. Hopefully I'll make some progress this weekend.

 

[Kiwi Canuck]

A quick recap of some of the work completed recently,

A quick recap of some of the work completed recently,

Some recent work done, some complete some not.
Chain installed, (stayed with the 630), still need to pick up a chain tool to crimp the link.
Clutch hub welded and clutch reinstalled, waiting on OEM screws for clutch cover.
Valves checked and new shims installed, needed 7 new shims, bought 2 OEM from my local dealer here just so I could measure what I needed, and then purchased 5 from the shim club.
Valve cover installed with new gasket.
Valve cover end caps installed, thanks Rich (VMASS) for the freebie replacement one I needed.
Carbs cleaned and almost back together, waiting on new main jets.

Here's some pictures from today.

 

[Nessism]

Bike looks fantastic.

 

[Guest]

Bikes looking great David!!

 

[ozman]

yup love this project, keep up the good work !

ozman

 

[John Kat]

Great work!
It's time to check if the frame is not bent...
I have rebuilt the exact same bike and discovered that the frame was bent when my project was finished
It's very easy to do so why hesitate?
I used a laser beam normally used to check chain alignment ( http://www.profi-products.de/en/products/profi-laser-tools/ ) to determine if the front wheel was straight ahead of the rear wheel.
The laser beam was set in turn on each side of the rear wheel by lying it flat against a flat surface positionned against the rear wheel .
You note the position of the beam on the floor at the level of the front wheel.
If the distances are not equal on eitheir side....you have a problem

 

[Kiwi Canuck]

Thank you

Thank you

Bike looks fantastic.

Well thank you for the compliment, I have seen your impressive rebuilds and take my hat off to you for such detailed and awesome photos and contributions to this site.

The pictures of your beautifully finished bikes when I first came on this site is what inspired me to take on such as full scale rebuild, and I will soon get the reward of all the hard work.

PS. I have also used your photos to see how parts go back together, because I forgot to take pictures myself.

 

[Kiwi Canuck]

Thanks

Thanks

yup love this project, keep up the good work !

ozman

Thanks Ozman, well at least we know where all the missing GS1000S's are now that we have seen a picture of your stash of bikes How many do you have there?


On a completely different subject, I was considering taking on a project to see how many "S"'s are out there and track all the known Frame Numbers and see if we could come up with a rough idea as to how many bikes were sold world wide.
I believe all bikes with frame numbers starting with GS1000 52XXXX are 1979 "S" models and GS1000 53XXXX are 1980 GS1000S but a few other GS1000 models may have also used the 53 series frame numbers.

If I was to ask for Frame Number (maybe engine Number as well) and country of original sale if known, and where it's located now. Would you see any issues with giving that info out?
I would keep it on an Excel spreadsheet and email it to people who have supplied the information once I've got enough info to make it meaningful.

 

[Buetra19]

I just read this entire thread! Awesome!

Now back to my 80 gs1000 in the driveway....

 

[Kiwi Canuck]

Installed Console tonight

Installed Console tonight

Finally bolted on the console, just test fitting a few pieces to see what goes where.
I'm lost when it comes to the cable routing, I have the manuals with the cable routes but they just aren't that clear to me just yet.
I think I have to do it the wrong way twice before my brain will interpret the instructions correctly.

Here's the console bolted in with the bolts upside down, now that I have rechecked the diagram.



You may have noticed the Front Brake assembly has been removed, well, see the next post for the story on that.

Under, over, behind ??? not sure yet were the cables go but I'm sure I'll get it soon.

 

[Kiwi Canuck]

Front Master Cylinder Leaking

Front Master Cylinder Leaking

Well , my first redo, and I'm sure it will not be the last, seems I pinched the new oring I installed in the M/C reassembly.
I remember it being very tight when I went to push it in, and it didn't feel quite right when it finally went in, oh well new oring seal on the way.

Will also need to repaint it as the fluid has softened the paint a little.

 

[Kiwi Canuck]

New Boots

New Boots

I purchased new boots for the air plenum but did not intend to install them as I had heard they were a PITA to install, well tonight I thought what the heck, I’ll give it a go.
First I tried to remove the metal retainers without destroying them, but that seemed pointless as I had new ones anyway. Thought I could donate the old boots as a complete set to someone who needs them as they are still useable but not perfect.
Anyway this is what they look like when removed by me.

The new boots went in very easily and with a little synthetic grease on the retainer they slipped in by hand nicely and needed only a little help to seat them, I used a flat head screw driver to push them the last mm or so. Once seated the rim of the retainer is not longer visible, see the 2 right ones are not seated yet.



Boots installed and test fitted on the bike.

 

[Kiwi Canuck]

Thanks

Thanks

I just read this entire thread! Awesome!

Now back to my 80 gs1000 in the driveway....

Thanks for kind comment, always appreciated.

I hope there is some value in what I'm posting here, I enjoy doing the work on the bike and I've started to really enjoy keeping this thread up to date and documenting my journey on this project.

I have a mental deadline to get the bike finished before "Vintage in the Valley" which is August 18th in Chilliwack BC, but I'm not sure I want to rush the project to get it finished as I'm really enjoying this now and don't want it to come to such a sudden completion.

http://www.vintagemotorcycleshows.com/

http://www.vintagemotorcycleshows.com/images/03bd880e67b14887abc9b9655d558dad_pusf.jpg

Cheers, KC.

 

[John Kat]

I've just taken my GS 1000 ST ( European model) apart and I took some pictures of the wiring just in case
Here they are:

 

[Kiwi Canuck]

I've just taken my GS 1000 ST ( European model) apart and I took some pictures of the wiring just in case
Here they are:

Thanks John that will help, really appreciated.
Do you have a picture from the right side head stock, where the cables from the handle bar controls and console go?
Do they go through the frame, like the wiring harness does on the left side, or around the outside?
I'm concerned about them getting pinched in the steering lock stop if I put them down and through the frame but that looks like were they go.

Thanks

 

[John Kat]

Thanks John that will help, really appreciated.
Do you have a picture from the right side head stock, where the cables from the handle bar controls and console go?
Do they go through the frame, like the wiring harness does on the left side, or around the outside?
I'm concerned about them getting pinched in the steering lock stop if I put them down and through the frame but that looks like were they go.

Thanks

On the right hand side, all cables go directly around the steering stem and then under the tank. They don't get pinched because they are high enough above the lower triple tree. I didn't take pictures but I looked at my other GS 1000s to confirm

 

[Kiwi Canuck]

Moving along, not

Moving along, not

Got a new batch of parts today, a bit frustrating because almost every thing I was waiting on parts for still can not completely finish as quite a few of the parts do not fit properly.
The diagram shows the part number, I ordered the correct part number, the parts show up but won't fit, guess Suzuki has a few items that have the incorrect numbers, Bolts too long, or too short, wrong size or type of oring etc. Nothing too big a deal just frustrating as I'm trying to see if I can fire up the bike before the end of the weekend but at this rate it isn't going to happen.

Oh well, I may resort to cutting the bolts with a hacksaw and heading off to my local Suzuki dealer to get the other parts.

I did get the Carbs installed but noticed the new Pipe Clamps do not tighten enough to stop the boots pulling off the rear of the carbs.
Not sure why but when I try to bolt the air box plenum to the frame, it does not line up, seems too low and when I pull it up to line up the top bolts the boots slip off the rear of the carbs.

Do the inlet boots at the rear of the head go on a certain way or are they reversible? They look reversible, I'm stumped as it seems like the carbs are almost 1/2" low when connected to the front boots only.
I wonder if the bike has the correct inlet boots installed? I believe the PO told me he changed the boots when he tried to get the bike back on the road in 1997.

I'll post some pictures in the morning. (if you want to see the inlet boots scroll up a few posts to see them, Posts 140 & 142)

 

[Guest]

On the 80' models, the intake boots are marked left and right with the marks at the bottom. If memory serves me right, the airbox boots need to be rotated the correct way so the carbs will align the best they can. It can be a bit of a bugger but once you've done it 8 or 9 times it starts to get a bit easier.

 

[Frank Z.]

Have the same issue re air cleaner being too low to bolt to frame. Tried a couple different assemblies ?given they're yet another 1-year-special part used on E and S models? and still 1/2" short of blissful unity. Annoying tick i know, but at least the dangly hairbox won't detract from usability.

 

[Kiwi Canuck]

Thanks AZR and FrankZ,
I'll take a look at my boots to make sure I have them on the right feet.
I may have to make an adapter plate to mount the airbox as I'm not sure I want to leave it unattached even though I considered that as an option.