New to me, GS1000GT

[dorkburger]

That is almost exactly what I did the Mac on my 1100e many years ago, minus the wrap.

 

[melchiro]

Right? These MAC baffles are JUNK!

Though, I do like the header design. I have these MAC system, on my two, CB-F Bikes, with my modified baffles, of course.

 

[free99]

*scribbling notes for my GS1000G*

Looks great Mel. I'm practicing some of the stuff you're doing on my GS450, no other way to gain experience otherwise.

How does one know if it's necessary to adjust intake/exhaust timing? Presumably it's because of the big bore kit?

 

[melchiro]

*scribbling notes for my GS1000G*

How does one know if it's necessary to adjust intake/exhaust timing? Presumably it's because of the big bore kit?

Hey there, since I had the head decked, .006? , this lowered the head down enough that it throws the cam timing off, several degrees.
And, with the existing cam chain with several thousand mile, it will have a slight stretch to it.

All added together, the intake and exhaust valves are not opening and closing at optimal times, in relation to the piston?s,
BTDC(Before Top Dead Center)or ABDT(After Bottom Dead Center).

Slotting the cam sprockets, in order to rotate the cams, to obtain the desired, ?Lobe Centers?, is what must be done.

I hope I didn?t get to Technical on you?

Mel

 

[melchiro]

Progress report.. Exhaust Flange/Collar work..

MAC Exhaust has the standard Chrome Steel metal flange. I don't like it.
My 1000G motor came with the stock, Suzuki Aluminum Finned exhaust collars. This is what I want.

Dirty collars.

Cleaned, with using my Harbor Freight Soda Blaster..

Next up, fabricating spacers for the Suzuki collars. Cut up a pipe, and welded stops on it, I made eight.

Then chop off the MAC Flanges.

Test fit the spacers.

Bought new Stainless Socket Cap bolts.

Test fit the header, onto the bike.

Fits nicely.

Yeah, looking like a KERKER, don't it?

Now that I know that the fit is perfect, I'll remove the header again and install the exhaust gaskets. then fabricate a hanger for the muffler.. Slow going, but it's getting there..

Mel

 

[dorkburger]

I love the idea of using the stock collars. I looks better, and they are probably much more rigid then the steel ones.

 

[steve murdoch]

Nice work on the pipe.
You sure it isn't a Kerker?

 

[melchiro]

Nice work on the pipe.
You sure it isn't a Kerker?

Hahahahahaha..... LOL... Maybe I can fabricate a KERKER badge... Better yet, I should make, ?Melchiro Exhaust? badge.. that will throw everyone off.. LOL

 

[melchiro]

Progress report for this weekend..

New Shocks.. Piggyback type, Ebay Shocks.

Mounted the shocks onto the bike. I fixed the adjustable lower eye for a total length of 340mm.

I fabricated a muffler hanger from piece of aluminum, to be bolted to the passenger peg bolt. Installed the exhaust gaskets and fully bolted down the exhaust flanges.. My homemade exhaust spacers worked perfect.
I installed the body panels, just to see what it looks like... I like it.

I installed the oil filter, just need to fill it up with oil.. I'm thinking the first engine start-up may happen this month??

 

[melchiro]

Today's progress report.. Fired up the bike.. Not without minor issues, of course. First, the starter clutch was slipping badly. You could hear it in the first video.

The second video, was after I tightened the rotor bolt, and cleaned the carb's idle ports. I still have to fine tune the jetting.

The MAC pipe with my home-made baffles, are loud...


First video.

Second video.

 

[dorkburger]

I?d swear that the birds in the background were mocking the startup attempt.
Glad to hear it run. Progress..

 

[KiwiGriff]

Awesome project. You, Sir, are a legend! Such a clever person - I believe there are many who wish they had the skills you have! Am just rebuilding my own 1000G but back to stock (except for a 4 into 1 pipe that was on it.) It had been sitting for years when I bought it back. Stripped carbs and cleaned, replaced bits (intake boots, petcock, coils, fluids), adjusted valve clearances, etc. Now just waiting on air cleaner boots to arrive from Z1 to New Zealand to be able to complete the engine work side. Then new shocks, new rubber and a nice tidy up. Love your work. Cheers, Griff

 

[steve murdoch]

Instantly recognized the slipping starter clutch. A different sound than the one on my CB1100F but the same result.
Can you glass pack the muffler or will you have to reconfigure the baffle or just be prudent with the throttle?

 

[melchiro]

Almost ready for it's maiden Test Ride.. Need to fabricate a left side mirror mount, bleed the rear brake and obtain new license plate registration tabs..

Fabricated a fairing mount & installed the new windscreen. Installed four new mini turn signal lights.. KOSO gauge works.

 

[1948man]

What a cool bike. About 1030cc? I'm sure you'll keep the 850 badges.

 

[melchiro]

What a cool bike. About 1030cc? I'm sure you'll keep the 850 badges.

With the 3.5mm oversize pistons, I think the displacement is at 1099.80cc, rounding up to 1100.. Yup, for sure, I'll keep the 850 body on this bike.. A real sleeper..

So some minor issues.. Like taking two step forward, then one step backwards.. I took the bike for a quick spin. This motor is strong. I found an intake leak on number one carb manifold. Bad O-Ring. Fixed that and now it idles perfectly.

Also, on that quick test ride, I was leaking hypoid gear oil from the secondary gear.. So I removed the swingarm and removed the secondary gear to discover the worn out oil seal... Ordered a new seal. Should be here next week..

Secondary Bevel Gear Drive.

The OIL SEAL, Part # 09283-35018. $12.00

 

[melchiro]

So I received the secondary gear main seal and installed it. Put my bike back together..

Then I took it out for a proper "Shakedown" Test Ride.. About 25 miles.. No leaks. Tracks straight. No wobbles. Handling feels stable.
Braking is strong with two fingers. Carburation & throttle response feels spot on.
Motor is strong.. Strong enough to slip the clutch when I "Rip" on the throttle.. I knew this might happen with the original plates, so I have a new set of friction plates to go in, after I do a proper "Break-In", of this motor. I'm thinking another 80 miles and then I'll change the oil and install the new plates.

Now that the "Mechanicals" are done, next up will be the cosmetics. Dent repairs and a paint job.. Yes, it will be Blue..

 

[steve murdoch]

Congrats, Mel.
I remember reading you are using Gixxer carbs and Dynojet. Just curious on your reasoning for stacks instead of pods?

 

[melchiro]

Hey Steve, the stacks were always on this set of carbs, so I didn?t change them... I do have a set of K & N, Pod filter on the shelf, for these BST34 ?Gixxer? carbs..
I am thinking of installing the pods, because once this bike is done, I most likely will be riding this GS more, than my other Hondas. The higher bars and the relaxed riding position, is much easier on my 56 year old body..

 

[Guest]

Hey Steve, the stacks were always on this set of carbs, so I didn’t change them... I do have a set of K & N, Pod filter on the shelf, for these BST34 “Gixxer” carbs..
I am thinking of installing the pods, because once this bike is done, I most likely will be riding this GS more, than my other Hondas. The higher bars and the relaxed riding position, is much easier on my 56 year old body..

I have been led to believe that no jetting change required between pods and stacks, so I intend to run mine with both based on what I'm doing. Taking it to a meet or show I'll run the stacks for the aesthetics, going on a longer several hundred mile ride or just day to day bopping around town, run the pods for better filtration. I am just now getting my 1000G (bored out to 1085) put back together after having to tear down a sticky clutch and sending the tank and fender out for paint, so yet to test that "no jetting changes required" theory.