New to me GS1000G

[Guest]

Your pipes sound like they are scrap metal. You can weld on some aftermarket mufflers though. I did that with an 850 once. Welded on a set of Dunstalls. Looks great but was a bit loud, although I never packed it with proper baffle packing only steel wool.

 

[JTGS850GL]

OK, got a chance to do some more work over the last couple days.

The good:
Replaced front wheel bearings.

Assembled forks with new seals, wheels and rebuilt front brakes. Still waiting on some master cylinder parts to complete front brake assembly.

Installed new stator.

Installed and wired in new SH775 R&R.

Polished and installed stator, secondary drive and clutch covers.

Installed carbs and airbox. Still waiting on gasket for breather cover.

Assembled exhaust components and installed exhaust gaskets in head. Still need to mount exhaust.

The bad (so far):
Clutch seems to be dragging even after disassembly, repack and reassembly. Need to inspect all plates for warpage and thickness. Will see what happens after I get her started.

Choke cable broken. New cable ordered.

Gas tank is rusty inside. Will clean with Rust Rescue. I'll decide on whether to use POR15 after that.

Exhaust mufflers rotted out but did find all needed clamps.

Fuel gauge is not working correctly. Need to check wiring and sender before I condemn the gauge.

Pictures to follow?.

 

[Big T]

If your tank is rusty, your fuel gauge sender is also rusty

 

[JTGS850GL]

Here's where she sits as of now:

Front end assembled but still waiting on a couple brake components before I can add fluid and bleed them. Still waiting on the new gauge back:

Pipes installed and derusted. Note on valve cover is to remind me the engine has no oil. Still looking for rectangular rear tail lights to match the front:

Carbs and air box mounted. Side covers polished up. Still waiting on emblems:

Replacement fuse panel installed and new R/R installed and wired in. Still have some clean up on mounting panel but that's for another time:

SH775 R/R mounted in the stock with just a minor amount of elongation of the mounting holes:

Replacement rear view mirrors came in as well:

Reconditioning the crash guards. One done and one to go:

Choke cable installed and instrument cluster getting buttoned up:

Still waiting on a number of parts but most are cosmetic. A few are critical though. I'll need them before I can start her up and begin the carb sync and tune process. Going to have to do some minor rust removal of the fuel tank as well.

That it for now... at least until some more parts arrive.

 

[JTGS850GL]

A little more progress:

New polished hex bolts and case guards ready for installation:

Began the process of stripping the tank for paint:

Here's where I am as of today. I coated the tank with oil to prevent flash rust:

Pretty surprised at how few dents and rust on the tank. Rattle can paint job came off pretty quickly with Aircraft brand stripper. Looked like it's been reworked before since none of the original paint was present.

The next step will be to de-rust the interior of the tank, fix any small dents and prime it for paint.

Still waiting on a breather gasket before I can try to start the engine after the carb rebuild.

Still concerned with the clutch not fully releasing when the engine is not running. Is it normal to not be able to crank the engine when in gear (clutch pulled in) without having the bike pull you down the road?

 

[JTGS850GL]

More parts arrived today so it was time to get on with it.

All the parts I needed to get the front brakes working arrived so I was able to fill and bleed the brakes. Still just a tad soft so I'll be tie wrapping the brake lever pulled in over night and see if that helps. Right now it feels much like my 850 so it's probably OK. Did pick up a little bling bling for the gauges:

New emblems did come in as well. The were indeed the later model black and gold emblems but I like them:

Started to prep the side covers for primer. Everything sanded down. The original clear coat was so bad that it just flaked off in most places. The covers had at least 3 different paint jobs so sanding them down took a little time:

New to me foot pegs arrived as well. Here's where we are today:

 

[eil]

Looking great!

 

[JTGS850GL]

Thank you!

 

[ged]

Looks like she is coming along very nice, well done.

Just for some info for me is the black wire from your RR going to an earth or is it to the negative on the battery. Regards

 

[JTGS850GL]

The black wire is going directly to the negative terminal of the battery.
The red wire is connected through the fuse block just like the original R/R.
The three yellow wires go straight to the three stator wires. No loop through the headlight bucket.

 

[Flyboy]

Nice progress, keep the updates coming, enjoying this build. :clap:

 

[JTGS850GL]

Ok, today was the day to get her started up. Connected the temp gas tank and let her fill the carbs... Opps, fuel coming out the airbox. Give the carb floats a little rap with the hammer and all's well. I did remove the air filter and clean everything out again before attempt 2 on starting. All buttoned up, choke pulled, pull the clutch and hit that starter... BINGO!!!!!!!! She fires right up and surges to about 3K RPMs.. or is it 11K or 5K or 3k.

Still need to do the carb sync, but one problem reared its ugly head once it was running. The tack would jump from 3K to 11K and them back. I disassembled the tach and found this:

Obviously the tach took a good hit at one point in it's life. The inner workings looked OK but I noticed that the needle would jump and hang while rotating the tach drive.

Looked like someone else had had their hands in there since the outer ring was already buggered up from a repair attempt:

I tried to lube it up but no glory. Still sticking and lurching even when I use a drill to drive the tach. I noticed that the tach would stick more when tilted then when held face on. I'm betting that it's toast and not worth the effort to repair. At least the fuel gauge is working. Looks like I'm in the market for a replacement Tach.

There is a little smoke coming from the left exhaust but the smoke started to diminish after a few minutes of running. I'll keep an eye on that. Once it idled I did a check of the charging system and measured 14.25V at 1500 RPMs. That's assuming that the tach was anywhere near accurate. Seems like the new stator and R/R are working as expected.

Brakes are firm now as well. Ordered a petcock rebuild kit along with new plug caps. Didn't really NEED the plug caps but figured if I'm going to spend the shipping for the petcock kit from Z1 then I'll just go ahead and pad the order with something that didn't cost much but would benefit the build. I know that many have had issues with the rebuild kits but I figured I'd give it a chance since the OEM petcock for the GS1000G is around $90.

I checked the clutch and all is good there. Shifted her through all the gears and pulled the clutch in only to see that the wheel would stop spinning as it should.


All in all a good day.:clap: A little cold in the garage so I'll wait for a warmer weather to do the carb sync.

 

[Guest]

Congrats! great progress today, always nice to hear them flash up isn't it. I sent a PM as well but I'll look around for a tach.

 

[JTGS850GL]

A little more progress today. Working on the fuel tank and preparing parts for paint.

Decided to go the rebuild route on the petcock since the one I had was in good condition and the price differential between new and used was $90 new to $22 rebuild. I know that many have had issues with getting the rebuild kits to work, but I decided to take it on and see what issues there were. The only problem I can see is if there is significant pitting on the vacuum driven diaphragm valve seat. I used very fine soapy steel wool (cheap Brillo pad) and was able to polish up the seat with no visible signs of wear. This is after I dipped and sonic cleaned the all the metal parts. After that I assembled the petcock with new part from this rebuild kit:

The final result was a working petcock that looked like this:

I checked all functions and everything looks to be in good working order. Vacuum diaphragm doesn't leak, the petcock flows with vacuum in both on and RES, the petcock doesn't flow when vacuum is removed and always flows when in prime mode.

Getting other parts stripped and ready for paint:

Tank stripped, scuffed and any small dents filled with Bondo:

Now I only have the last item to strip and remove the dents:

One problem area on the fender is a dent that needs to be worked out:

In the end I plan to use the PPG Deltron system for paint. I plan is to use DPLF50 Epoxy primer/sealer first with DP401LF catalyst, then a K36 sandable primer/resurfacer, then DBC base coat with DX57 activator and finally DCU2010 clear coat. I've always used PPG so that's why I'm planning on using it. If others have some better suggestions then please chime in. This is the first motorcycle repaint I've done but I've done numerous cars in the past.

 

[JTGS850GL]

OK, it's time to start thinking about paint and color. My plan is to use PPG as the color supplier. Basically for two reasons. I've used PPG in the past and I have a good local jobber that can supply me with what I need. Basically using the Deltron 2000 system from primer to finish clear. The big decision is what color??? I've been thinking of a nice red metallic or metallic pearl. Here's one that I was looking at. It's a Lexus paint code 3R1 and the color is called Matador Red Mica:

Not completely set on this color so any other options or suggestions would be helpful.

 

[SVSooke]

That or it's very close Toyota relative is the red on the 85 750

Looks quite bit darker in shady or cloudy conditions but in the sun it's just WOW!

 

[JTGS850GL]

No other suggestions on color?

 

[BluePlateSpecial]

That looks close to the Toyota Salsa red I did on my CB400-

Honestly, if I had it to do over again and I had the money I would have either done the UK spec stock cb400 candy red I really wanted or would have done a true candy.

I liked mine but it was easy to see that it was a modern color and in my opinion that just doesn't quite look right on an old bike.

 

[BluePlateSpecial]

I like the two-tone dark blue/green/black with a metallic silver or gold that I have seen on several GS's. I think the dark colors lend themselves well to a bigger bike but the metallic helps to break it up.

 

[JTGS850GL]

More pictures please. Hard to visualize the outcome with all the different colors listed.