Progress!!! 1978 GS1000E Restoration/Performance Rebuild

[philosopheriam]

At any time during this post, anyone reading is fully allowed to poke fun at me for being OCD.

So, I wasn't happy with the clutch cable that my buddy and I fabbed a couple weeks ago - the 90deg bend at the clutch lever had a fairly tight radius, moreover, it dropped down right where the headlight bucket bracket is supposed to go. So, I did some searching and came up with plan B.

I needed a cable with a longer, more gentle 90deg bend at the clutch lever. I saw the cable for a GS1000S on Ebay and it seemed to fit the bill - got a NOS one for $20. Compared to the overall length of my old cable, it was about 6" too short. So, we cut the upper portion of the GS1000S housing (that had the crimped 90 degree bend) to the same size as the previous upper housing. We then re-used the center adjuster and lower housing from the old cable. The inner cable wire had to be remade, as cutting the ends off the old one rendered it too short. Also, the NOS GS1000S cable came with new rubber bits, threaded end adjuster, and an end spring, so we used these items, as well. Here is the finished product:





Here's what it looks like on the bike:



Overall, it works incredibly well and the more gentle bend at the clutch lever has made the pull significantly easier.

 

[philosopheriam]

Here is another solution to a minor problem - I hate the look of zip ties, and I don't like the way they chafe a freshly powdercoated or painted surface. However, they have the ability to secure wiring snugly, which the OE harness straps do not. I wanted the best of both worlds, so, I came up with this idea - put a small piece of high-temp expandable poly sleeving on the zip tie. It will prevent excessive chafing, it will hide the appearance of the zip tie, and it will look like a finished product.

 

[SVSooke]

OCD?You? Never crossed my mind:topsy_turvy:

 

[80GS850GBob]

OCD?You? Never crossed my mind:topsy_turvy:

awh man...where are my boots?....{lol}

 

[80GS850GBob]

Myself, I've gone with the snug fit heat shrink tubing {un heated} over black zip ties....but your set up is nice too.

Oh, thanks for the heads up on the cable...it's all still in the possible design phase...but that's where new things start.

 

[philosopheriam]

OCD?You? Never crossed my mind:topsy_turvy:

I know, the reputation is earned

 

[philosopheriam]

Myself, I've gone with the snug fit heat shrink tubing {un heated} over black zip ties....but your set up is nice too.

Oh, thanks for the heads up on the cable...it's all still in the possible design phase...but that's where new things start.

I like the expandable poly because it has a bit of lengthwise stretch to it - when you properly size it to the diameter that it will be wrapping around, it gives you about a 1/4" of play so that once the zip tie is snugged down it won't bunch up if it's a hair too long.

 

[mike54]

I like the expandable poly because it has a bit of lengthwise stretch to it - when you properly size it to the diameter that it will be wrapping around, it gives you about a 1/4" of play so that once the zip tie is snugged down it won't bunch up if it's a hair too long.

You can get rubber cable ties from ducati suppliers such as Bevel Heaven and European supplies such as classic motorcycle spares. There are also velcro ties from McMaster Carr. I like to use those for mock up and on my track bikes because they can be reused easily. I might try the expandable poly over the velcro strap to see how that works.

 

[andy10889]

Thank you for taking the time to put all this up. Its been a real pleasure to read through all 45 pages and watch this bike transform. Cant wait for the finish shot with all the body work on.

 

[philosopheriam]

Thank you for taking the time to put all this up. Its been a real pleasure to read through all 45 pages and watch this bike transform. Cant wait for the finish shot with all the body work on.

Thanks buddy - I'm just waiting on some parts to be finished by my powdercoater and then the final final final assembly will begin!

 

[philosopheriam]

They're baaaaaaaaaaaack!

Last batch of parts from my powdercoater:


Final assembly begins tomorrow

 

[jsandidge]

Looking forward to it.

 

[philosopheriam]

Progress, 7/10

Bad news item #1:
I bought a pair of used calipers a couple years ago to use with Salty's brake upgrade - when I took them apart, the pistons were in mediocre condition and the bores/seal grooves were very questionable. Instead of powdercoating them, I painted them, so if the calipers were junk I wouldn't be out the powdercoating fee. Long story short, the caliper paint I used chips when you breathe on it, and the calipers are starting to look like $hi* - moreover, they do not perfectly match the color of my frame. So, the front calipers went in the garbage can and I bought a used set from an 05 Concours (with a 30-day guarantee). These will be going to my powdercoater in the near future.

Bad news item #2:
The seal in my old gas cap was marginal, but I was going to attempt to polish the cap and reuse it - I soaked the seal in silicone spray to get it to swell a bit. During the polishing process, I accidentally caught the edge of the cap with the buffer and it sent the cap flying out of my hand and into the concrete floor. Now the cap is dented and scratched. I guess I'll be buying a new one now....


On a happier note, I fired up the zinc plating rig to take care of a few items that totally slipped my mind:


Installed the rear turn signals:

 

[SVSooke]

Progress, 7/10

On a happier note, I fired up the zinc plating rig to take care of a few items that totally slipped my mind:

I'm defiantly stealing this idea for my next plating adventure Sorry to hear about the bad stuff

 

[Guest]

I follow many of the builds, but have never been motivated to comment until now. With having an electrical background I can see the effort that's gone into the wiring loom. The quality and attention to detail is phenomenal. Take a bow Sir !!

 

[philosopheriam]

I follow many of the builds, but have never been motivated to comment until now. With having an electrical background I can see the effort that's gone into the wiring loom. The quality and attention to detail is phenomenal. Take a bow Sir !!

Thank you, sir!

 

[clock1958]

Hi Mate

I have a 1979 / 80 GS1000S which requires a new wiring harness and just can't get my hands on one anywhere? Can you offer any pointers?

Mark
Sydney

 

[philosopheriam]

Hi Mate

I have a 1979 / 80 GS1000S which requires a new wiring harness and just can't get my hands on one anywhere? Can you offer any pointers?

Mark
Sydney

Mark - not trying to be an a-hole, but why does it need a new harness? Is the original missing or buggered beyond repair?

 

[switz1]

http://www.ebay.com/itm/Suzuki-GS10...ash=item3d20088cbd:g:9GYAAOSwayZXi7zw&vxp=mtr

 

[philosopheriam]

7/17, Progress

Headlight bucket, bracket, spacers, and turn signals installed:





Electrical stuff reinstalled after powdercoating: