chain/sprocket conversion and new header

[KGB]

As many of you know, I made some changes to my 1980 GS1000S.

The first was going to a 530 chain and sprocket set.
I really notice the "hookup" with this setup.
No jerking and snatch on launch.
I used 2 7/8" washers, one on each side to shim the front sprocket.
I kept the gearing stock 15/42. I bought steel sprockets, not aluminum.
One thing to keep in mind is the physical difference in link length.
I went from about 100 link 630 to about 115 link 530.
I think the rubber cush drive on the front sprocket was the noise culprit.
Any time I would engage 1/st gear, a loud thunk or thock noise.
Lots of lash in 1/st gear, now all gone. And alot less noise.

I also changed the exhaust from a very old,15+ years, Kerker to a V&H 4>1. Big difference in mid range and top end.
The header section to the collector on the V&H is shorter than the Kerker model. The V&H is tucked in tighter also. I can still get to the oil filter and drain plug. I was also able to keep the center stand.
The muffler/baffle section of the V&H is longer than the Kerker.
It's also a lot quieter. I'm sure the Kerker baffle was shot to $hit.
The V&H muffler is positioned in such a way that I can't use the right side passenger peg. Bummer, my wife is not real happy right now.
I need to fabricate a bracket to extend the peg or bend it up and over the muffler.
The V&H is becoming a nice gold color, not blue like the Kerker was.
I guess I got lucky with the jetting.

So we're running fine and have been riding for 2 days. No leaks, nothing has come loose. About 200 miles so far.
Monday is going to be a 300 mile day

I also replaced the front brake pads with EBC organics. They're still bedding in and seem to be ok. Haven't tried them in the rain yet.

So after 3 weeks of arguing with MAW about the defective V&H system, they did ship another, no overnight or priority shipping......
No customer service skills either.

 

[KEITH KRAUSE]

How about the rear sprocket? What is done to keep it in line with the new "shimmed" front sprocket?
I've been thinking about this conversion too on my '79 GS1000E.
I'm a bit confused. I realize the newer bikes make a lot more power and use smaller chains. These smaller chains either wear out real fast or are made of a better quality material? My favorite brand, DID, costs nearly $140 for a 96 link 630 o-ring. I would think its quality is very good. What's the cost of the new 520 chain? Do you still run o-ring? What's the estimated mileage you hope to get out of the new chain? What made you decide on 520 instead of 530, etc?
Sorry for all the questions. I just figure you've done a lot of research.
Too bad about the pipe interfering with the peg. I questioned you earlier about the way they've changed their pipe flanges. I was thinking of buying another new one, just for a spare someday. Now I don't know if that's a good idea. The one I bought in 2000 (with welded on flanges)bolted right up, no problems. I don't know why they have to mess with a good design? Not only have they changed the flanges, I guess they've changed the megaphone shape too.

 

[saaz]

From what I read most people never own a bike long enough to change a chain these days. Dink is running a 530 on the 1150, so I am sure it gets a good workout.

My original 630 chain on the GS lasted 70,000kms. A replacement oring 630 lasted 20,000..amazing! It was a cheapie, but not worth it really. My current non-oring chain has lasted longer.

I will be going for a 530 chain next time, as I will need to do sprockets. 630s are just not very common, but you can pick about 5 different sorts of 530 oring chains off the shelf at the local shop for half the price of a 630 oring. 530s seems to be quite common (CB1300, GSX1400, Busa etc) so that may be the size to go for.

Do you get the CB1300 over there? I know the GSX1400 has not made it.

 

[Billy Ricks]

Going to a 520 actually helped me with sprocket alignment. I run a 160 on the rear so the rear sprocket was out farther than stock. I ground down an old front sprocket to use as a spacer. It still didn't get the chain running quite straight. Once I did the 520 conversion that brought the outer edge of the rear sprocket in about 1/8". That put the sprockets damn near perfect.

 

[KGB]

How about the rear sprocket? What is done to keep it in line with the new "shimmed" front sprocket?
I've been thinking about this conversion too on my '79 GS1000E.
I'm a bit confused. I realize the newer bikes make a lot more power and use smaller chains. These smaller chains either wear out real fast or are made of a better quality material? My favorite brand, DID, costs nearly $140 for a 96 link 630 o-ring. I would think its quality is very good. What's the cost of the new 520 chain? Do you still run o-ring? What's the estimated mileage you hope to get out of the new chain? What made you decide on 520 instead of 530, etc?
Sorry for all the questions. I just figure you've done a lot of research.
Too bad about the pipe interfering with the peg. I questioned you earlier about the way they've changed their pipe flanges. I was thinking of buying another new one, just for a spare someday. Now I don't know if that's a good idea. The one I bought in 2000 (with welded on flanges)bolted right up, no problems. I don't know why they have to mess with a good design? Not only have they changed the flanges, I guess they've changed the megaphone shape too.

I didn't do anything to the rear sprocket as far as alignment goes.
I spun the rear wheel, no even close to touching anything.
I ran it in gear, on the center stand, nothing touched.
I went to a 530, I think I said a 520....

Yes it's an O-ring, DID brand. 132 links for $88. The shop does lots of business with us. I ended up using about 120 links.
I have a 1100 swingarm, not the stock 1000S swingarm.

As to the pipe, none of the flanges were welded onto the pipe, on either pipe I rec'd from V&H. It did bolt right up ok, and the muffler/baffle slipped on fine. This pipe tucks in tighter than the Kerker.
I ended up bolting directly to the foot peg braket. The kerker had a hanger.
I'm going to a friends shop next week to see if a Harley peg will fit.
The old GS passenger pegs were/are very thick on the rubber.
All I need is about 1/4 to 1/2"

Otherwise all is well.

 

[oldschoolGS]

Billy, where did you get your sprockets from. I have been checking and the only 520 sprockets I see are for modern bikes. I was thinking of going to the 520 setup to also help with allignment as I now have the 4.5in rear that I plan to run a 160/60 on. What chain did you use and what is your setup as far as gearing and chain lenth. Thanks, Ed.

 

[Billy Ricks]

Ed,
It's been awhile so I don't remember exactly where I got the set. The shop sells Vortex sprockets on Ebay from time to time. Moto-something or other. I got Vortex front and rear. You need the 520 conversion for 90-95 GSXR750 models. I got a Regina o-ring gold chain, stock length. The only difference is the width of the chain. Everything else about it is the same dimensionally. I went with a 16/43 combo. You could go with a 17/43 and still be okay. Check out Vortex' website. This isn't who I dealt with but they have about the same offer, http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=2481978448&category=35600.

 

[oldschoolGS]

Thanks Billy, the thing I was concerned most with was the countershaft sprocket-I had no idea what newer models used the same sprocket as the GS. Put another beer on my tab. Ride On, Ed.

 

[Anonymous]

I'm a bit confused. I realize the newer bikes make a lot more power and use smaller chains. These smaller chains either wear out real fast or are made of a better quality material?

The OEM 530 chain on my 97 ZX-9 has 23,000km on it and looks like new. I bought the bike last year with 11,000km on it and have not even had to adjust it in the ensuing 12,000km I have used it. I will be unhappy if it does not make at least 30,000km before needing replacement. I have heard of OEM 530 chains going over 30,000 miles on other ZX-9's, so a well cared for chain should go many seasons for you.

The shop sells Vortex sprockets on Ebay from time to time. Moto-something or other

That would be "moto-heaven". A buddy talked to him about a 520 conversion for an 89 ZX-10 and he was very helpful and quite knowledgable about the older 80's bikes. He has a current listing here:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=2482175324&category=35600

HTH,
Mark

 

[Anonymous]

Hi guys I had this explained to me by my facorite bikeshop
The chains have different tensil strength a really strong 520 chain could be stronger than a (cheap) 530 chain.
This is what they told me feel free to correct me if I'm wrong.
Mikey

 

[oldschoolGS]

I talked to Richard this morning at JT Sprockets in Atlanta. He was very helpful- he spent about 15 minutes on the phone cross referencing all their inventory to find something that will work. My dilema is that I am using a 2001 Katana rear wheel so I need sprockets that will match the Kat rear and the GS front. Their website has all the sprocket dimensions on it-you can find what years will interchange with others easily. He set me up with a 15 tooth steel front and a 45 tooth alloy rear in 520 size. They do not sell to the public so you must order thru a supplier like Tucker. Now I just need to buy the 520 chain-I will probably go with a 120 link chain and shorten it as needed. Thanks for the help guys, Ed.

 

[Billy Ricks]

Ed,
You might want to consider the Vortex front. It has about 1/4" offset built into it. Also the 15/45 combo is going to be pretty high. I started off with 14/40 and it was too high. The 520 conversion is 16/43 and could stand to be a little lower. It's good for about 135 at redline, but with my mods I could pull a little lower gearing.

 

[Billy Ricks]

Ed,
Does your sprocket carrier have 5 or 6 bolts?

 

[oldschoolGS]

I have been running 15/45 with the 802cc kit, it is a little high at 3.0 but I like the off the line acceleration- I do not even come close to top end speed anymore. I have hit top of 4th gear on the TL at 135 and that was almost too fast. The new rebuild will be 816cc so it should really go like hell down low. I did notice that one of the JT steel fronts has an offset- the other is flat. You just confirmed that I should probably order the one with the offset as I might not even need a spacer with it. Thanks, Ed.

 

[oldschoolGS]

One of the problems is it has 5 bolts. They only had one rear available in that bolt pattern- the 45 tooth rear alloy. I have not ordered anything yet-I probably need to check around to see if any other rear is available. The front looks unchanged- The 90-95 GSXR fits the GS just as you said in addition to the Katana 750 all years. Thanks, Ed.

 

[Billy Ricks]

That should be the same as the 90-95 GSXR750 conversions. My 4.5" wheel only has 5 bolts for the carrier.

 

[Billy Ricks]

BTW, Vortex has them with any number of teeth you want. Check their website, you can order directly from them. Really nice sprockets.

 

[oldschoolGS]

Excellent info, Thanks, Ed.

 

[oldschoolGS]

JT Sprockets website only shows the 5 bolt rear sprocket up to 1989 for the GSXR750. 1990 and later used the 6 bolt pattern. The 1985-1989 GSXR sprockets all interchange and use the same front as the 83 GS750. The Katana looks like it kept the 5 bolt pattern after the GSXR went to the newer size.

 

[Billy Ricks]

Ed,
I remember what it was I ordered now. Check the Vortex website. The sprockets I got were for '89 and up GSX600F models. Bikebandit shows them having a 5 bolt pattern.