Early 1978 GS1000E project B/G

[Frank Z.]

Cool! Nice find, Daniel. Subscribed!

 

[Hoosier Daddy]

Didn't get too much done on it today.
...
Pic's tomorrow.

Daniel

Sounds like you got a lot done to me!

 

[7981GS]

Concentrated on finishing the front end today.
Made the 1.2" spacers for the progressive springs and filled with 12.5 Wt. fork oil.
Re-built and greased the speedo drive.
Repacked the front wheel bearings with synthetic grease.
Re-painted the '80-up slotted rotors and milled out the record scratches to give them a new surface for the new pads to seat into.
Smeared some white grease on the brake surface before painting.

One example of what I started with:

After paint and resurfacing:

Old brakes and rotors:

Upgraded '83 Katana brakes with new GG rated EBC pads and surfaced rotors:

Vastly improved front brakes using stock parts and no expensive parts from other manufacturers bikes and adapters. Simple. :wink:


Daniel

 

[hp1000s]

I'm using that same front brake setup on my S, with great results...it's not like twin pistons, but alot better than the original stuff. Good job.

 

[7981GS]

Replaced the PO's bolts to secure the seat:

Installed the seat that I planned to use on the Cooley on it (for now) with the correct factory pins:

Installed the 1100ES handle bar and took her out for a couple of pic's.
She looks darker in these pic's than she is.
I still need to do the rear brakes, change the oil/filter, change headlight/ears,
turn signals, tank badges, mirrors and install the chainguard:

Put a couple of gallons of gas and 8 ounces of Berryman's B-12 in it.
Replaced the hard as rock fuel line and filter with new hose and clamps.
The PO already had a couple of extra grounds added and a different rectifier in it.
I still added a clean 12ga. ground.
With the battery borrowed from Goldy, I tried to start it.
Still need to fine tune the carbs and replace intake manifold O-rings, etc.
Here goes nothing! .....

http://www.youtube.com/watch?v=JuQcgd8khVo


Valve adjustment and all of the usual electrical clean ups still on the to do list also.
She is at least getting there. And RUNS!


Daniel

 

[7981GS]

Pulled the plugs and saw no surprise:

They all looked just as good.
I cleaned them up, gapped them to .028 and tried it again. Runs a little better.
I will have to give the carbs the full treatment as it obviously hasn't been running right for the PO.

Daniel

 

[7981GS]

Update.

The carbs are 33 CR Special smooth bores. Probably WAY too much for this stock motor.
I will either sell them or use them on an 1166-1261 4-valve motor.

Intake manifolds were all finger tight except for this one that thought about giving me trouble.
As it was already partially stripped head, I just beat this into the screw and it also fell out.

Some of the air leak, besides the manifolds being loose, could have something to do with this:

RobertBarr and Cycle O-rings to the rescue!

Going to pull the cam cover and see if it even has after market cams to justify these carbs or not.
And adjust the valves, of course.


Daniel

 

[Guest]

Movin' right along Daniel, you're making real quick progress on this and you'll be done in no time

I reckon you could be onto something with those O rings...

 

[7981GS]

Measured a couple of cams and they are stock and within acceptable range:

Not going to waste these CR carbs on a stock factory motor!


Adjusted all of the valves using the factory tool and they are now all within range.

Ready to button up after re-torqueing the cylinder studs.

I am going to replace the carbs with a set of 32CV carbs that I already set up for a GS1000.
They fit the stock 28mm stock carb. intake ports.

Daniel

 

[FLHGSRay]

That tank info might explain why I have what everyone insists is a '80 tank with a levered petcock on my '79. A conversation about it is on page 2 of this thread. http://www.thegsresources.com/_forum/showthread.php?t=176796 Getting ready to do the same brake swap on mine. Have '82 discs, calipers, and m/cs coming, along with the aluminum swingarm. Any tips or warnings are welcome.

 

[drivera84]

quick progress on this bike!!! Do you have to replace the seals everytime you open the camshaft?

 

[7981GS]

Cleaned the cam cover in the parts washer and really had to scrub some of it with a steel and brass wire brush
to get off some of the stubborn stains, glue and gasket goop.
Wire wheel to the bolt heads and threads and torqued to 84 inch pounds with anti-sieze on the threads.
Installed the 32CV carbs.

That is it for today...

Daniel

 

[7981GS]

84, I was trying to re-use the gasket but it broke getting it off so it got a new one.

Daniel

 

[7981GS]

FLHGS, on some of these frames, you may have to spread the rear of the rear foot peg supports for enough clearance for the aluminum swing arm.
It won't be much if you have to. A bottle jack with the port facing up can do it easily.

Daniel

 

[TheCafeKid]

I'm not saying they won't work because frankly I've never tried it so I don't know, but if I'm not mistaken the CVs on a 1000E (80) were 34s. Those 32s might be a bit lifeless even on a stock motor. Generally speaking, and from the mouth of my Obi-Wan like teacher Terry, vacuum carbs have to be quite a bit larger than their mechanical counterpart. IE, the VM types on a 1000 were 26s, the BS types were 34s. Conversely, and I'm not sure what sort of maths are involved to come up with a equivalent from one to the other, those 33CRs would, and I'm guessing, be like sticking a set of 40+mm vacuums on it.
There are guys who use 33CRs on stock-ish ZRXs that see mostly track use. That's a 1200cc motor, and quite a bit "hotter".
Having said all that, they may work just fine but seem a little choked off. I'll be interested to see what your findings are.

 

[7981GS]

TCK, they will work just fine with the tiny 28mm ports of the early heads.
No restriction at all, quite the opposite.
Suzuki used the 34CV's on the improved larger port heads.

Daniel

 

[TheCafeKid]

TCK, they will work just fine with the tiny 28mm ports of the early heads.
No restriction at all, quite the opposite.
Suzuki used the 34CV's on the improved larger port heads.

Daniel

So then 32s will fit in VM heads? Like I could use those on an 8v 750? I never tried that. Just assumed they'd be too big. That's good to know. Thanks!

 

[7981GS]

So then 32s will fit in VM heads? Like I could use those on an 8v 750? I never tried that. Just assumed they'd be too big. That's good to know. Thanks!

I am pretty sure that you may have to use the 850 or 1000 intakes though.
Aren't the 750 manifolds smaller and don't they use 26mm carbs?
It has been over 16 years since my 750 had other than 850 head/cylinder and 34CV carbs.
As a matter of fact, I was looking at a set of smaller manifolds that I have today and wondering what they were from.
I have never owned smaller than a 750 Suzuki GS. Perhaps they are from it when it was stock?

Daniel

 

[7981GS]

So then 32s will fit in VM heads? Like I could use those on an 8v 750? I never tried that. Just assumed they'd be too big. That's good to know. Thanks!

I can actually check tomorrow as I still have a 750 small port head laying around.
I'll see if the 1000 manifolds will fit on it with another set of 32CV's.
I can even measure the ports of both motors.
If you wish.

Daniel

 

[FLHGSRay]

Not trying to hijack

Not trying to hijack

Just trying to get some good info out there. PO of my '79 GS1000E said this was the only tank he could get when he needed a replacement. I didn't ask when. Bike was black when new. I'm told the paint job looks like an '80, but the petcock is the levered type not used on the '80.