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New to me GS1000G

azr said:
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Make sure you seal the rubber boot around the piston/gear properly when you put it back together.
Click to expand...

I started on redoing mine and came across a minor issue. How do you get the wheel side drive gear out without removing the rubber seal? I see in your picture that the seal is still installed in the housing but the gear us removed.
 
A little more progress today. The new seat cover came in so I installed it:
jxc8.jpg


2oyn.jpg


The cost of the Saddlemen seat cover was $57 with free shipping on ebay.

Installed the replacement oil pressure switch as well. Much thanks to GSX1000E for providing me with such an excellent part:

dcxa.jpg


I know, I know I have much cleaning to do. Just can't get it done until I get a front wheel back on. Need to roll it out into the driveway to hose it down. In the mean time I'm letting the degreaser work on the more stubborn areas. Some of the oil you see came from removing the stuck intake bolt.

Cam covers were in fantastic shape so I installed them as well:
bjgc.jpg


Waiting on some parts to get things wrapped up. Still waiting on wheel bearings, stator, stator cover gasket, R/R, Misc. front master parts and screws. I hate shipping. Adds cost and time delays but it's just one of those evils you learn to live with.
 
JTGS850GL said:
I started on redoing mine and came across a minor issue. How do you get the wheel side drive gear out without removing the rubber seal? I see in your picture that the seal is still installed in the housing but the gear us removed.
Click to expand...


The rubber seal does not come out. The drive gear isn't wanting to come out because it's gummed up with crud, that and the rubber seal is probably a bit hard so the gear don't want to come past it. Soak the heck out of it and use a large pair of pliers and just keep working at it, you could use a bit of heat as well to soften up the rubber but be careful, there's no second chance. Post up a picture of where you're stuck with it, that might help. I've got a saddleman on my 80' 1000G as well, works perfectly.
 
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Mine has a tiny setscrew that I assume holds the driven gear in place. Due to crash damage, the housing has a ding in it that I think is preventing removal. I didn't have time to get fully involved.
 
Got a little more work in today. I decided to go ahead and remove the stator cover in advance of the new one arriving. Here's what I found:
pxc4.jpg


The wires were so brittle that in some places the insulation had fallen off:
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I did check continuity again and the stator still measures .7ohms between the windings and the armature. Definitely toast.

While the cover was off I decided to do a little cleaning up. This is what the cover looked like at first:
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After a little aircraft stripper and some wire brushing on the bench grinder I got this:
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qe0d.jpg


Then after some 1000, 2000, 2500 grit soapy wet sanding some cheap soapy brillo pads and finally the Mother's I got this:
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zfrs.jpg


Time to rest my hands and wait for more parts to arrive.:D
 
That stator cover looks great! Event the suzuki emblem.

I need to get back on mine. The one from the engine that came on the bike was rashed up so I have to use the one from the parts bike that is badly pitted and it sucks. Already put a few hours into it and I'm not even finished with step one.

I get lots of compliments on the clutch cover and forks that are done though! Gives me some motivation to get the rest done.
 
Plan to pick up a new emblem for the cover. Should look great with the contrasting black in new condition.
 
It's gold though unfortunately. The black ones come up on ebay from time to time or you can have go at painting the one you have. I've done not too bad with a bit of Vaseline to cover up the shinny parts.
 
I was thinking of painting it black and then lightly sanding at the letters as an experiment. I'll see after I get the newer gold one in. Worst case is I use it on my GS850... or the next bike.;)
 
Some more goodies arrived today:

The SH775BA R/R arrived. Not in bad condition for a used regulator:
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The mating connectors arrived today as well:
pyfc.jpg


Also received the stator cover gasket. Came from someone that ordered one and then wrecked his bike so he gave it to me for just the shipping:

1ejd.jpg


Still waiting on the stator but it wont ship until Wednesday.:( I'll be doing some more cleanup until it arrives. Can't have too much shine you know.:D
 
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Received the parts needed to install the new stator and the now polished clutch over. What's the best way to install the covers? Should I use any type of gasket sealer or install with the gasket alone. The clutch cover was covered with RTV. I know it's not a good idea to use it so I removed all the old RTV and now asking for opinions on what to use.

I'll post pics once everything is installed.

Next step is to install the carbs and airbox. After that I need to install the new R/R and get her running!!!
 
Gaskets go on dry. I think the only thing on a GS that gets sealant is the case halves. Non-hardening gasket dressing or a thin smear of grease can be used on the cam cover to try to get more than one use out of that gasket.
 
Gaskets go on dry. I think the only thing on a GS that gets sealant is the case halves. Non-hardening gasket dressing or a thin smear of grease can be used on the cam cover to try to get more than one use out of that gasket.
Click to expand...

+1
Gaskets go on dry, I use a very thin film of light all purpose grease, that is all.
makes cleaning the gasket surfaces next time, a breeze, and as Dogma says, if you are careful, you can save the gasket and use it again.

RTV is real shade tree mechanics, I, want to throw a wobbly when I see a motor put together with tubes of RTV, :mad::mad::mad:
 
Dry it is for sure. I do carry a small tube of "the right stuff" by Permatex on all my bike trips now though. I really think a tube of this, or any other tried and true high heat gasket maker, should be in everyone's took kit.
 
Dry it is. Thanks for the input guys.

Should be ready to install the carbs and airbox over the next couple days. The exhaust is another issue.

The bike came with the stock exhaust but the chrome is getting very thin in some places, it missing some of the clamps and the baffles are completely rusted out. I can hear the baffle remnants move around when I tilt the pipes back and fourth. Considering picking up a pair of V&H 4into1's but still wondering what to do with the stock exhaust? Are these pipes worth anything?
 
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