Project Beast back on track

[Guest]

After much delay, I'm working on getting the Beast project ('78 GS1000E) going again. I've had most all the parts to get the engine back together for a long time. After riding PJ's monster (80GS1000), I'm motivated to get 'er done!

Here's the specimen:

That engine will come out and become my spare, and a rebuilt engine will go in it's place. The new engine is/will be bored to 1085, welded crank, 750 oil pump gears, billet clutch basket with heavy duty welded backing plate, new degreed cams, sloted cam sprockets, manual cam tensioner, ported head, new valves with 3-angle grind, VM29 smoothbores, K&n pods or velocity stacks, and a 530 chain conversion.

The frame will have extra bracing added and powder coated. As of now, I'm going to go with an 1150 front end and 1150 wheels and brakes, 1100 swingarm, and some Ohlins for the rear.

All the engine work is done. I just need to buy the cams, sprockets and chain tensioner.

Here's where I'm at as of today. I got the crank and tranny back in and the cases put back together. I replaced all the phillips head screws behind the clutch.

Welded crank:

Back together with 750 oil pump gears:

 

[Guest]

Today I should get the bottom end finished. Here's some pics of the clutch that's going in:

 

[Guest]

The engine parts have already been painted gloss black. I'll be using chrome bolts on the side covers and head

 

[80GS1000]

Nice work Bruce! It's gonna be a rocket when you're all done.

Might want to think about adding an oil cooler and a Pingel fuel valve - my engine runs a LOT hotter and is a bit thirstier now that it's been bored to 1100cc and has hotter cams.

 

[Guest]

Nice work Bruce! It's gonna be a rocket when you're all done.

Might want to think about adding an oil cooler and a Pingel fuel valve - my engine runs a LOT hotter and is a bit thirstier now that it's been bored to 1100cc and has hotter cams.

It will have both. I already have the oil cooler adapter and an 1150 oil cooler.

 

[Nessism]

Nice work as usual Bruce. Looking forward to watching this thread.

Question: what kind of engine paint are you using? Very shinny and smooth as glass.

 

[srsupertrap]

After much delay, I'm working on getting the Beast project ('78 GS1000E) going again. I've had most all the parts to get the engine back together for a long time. After riding PJ's monster (80GS1000), I'm motivated to get 'er done!

Here's the specimen:

That engine will come out and become my spare, and a rebuilt engine will go in it's place. The new engine is bored to 1085, welded crank, 750 oil pump gears, billet clutch basket with heavy duty welded backing plate, new degreed cams, ported head, new valves with 3-angle grind, VM29 smoothbores, and a 530 chain conversion.

The frame will have extra bracing added and powder coated. As of now, I'm going to go with an 1150 front end and 1150 wheels and brakes, 1100 swingarm, and some Ohlins for the rear.

All the engine work is done. I just need to buy the cams.

Here's where I'm at as of today. I got the crank and tranny back in and the cases put back together. I replaced all the phillips head screws behind the clutch.

Welded crank:

Back together with 750 oil pump gears:

Nice work Mr. Bruce. BTW, what exactly is the benefit of using the 750 (years? 77- 80) oil pump gears. I take it you replaced both of them?

 

[Guest]

Nice work as usual Bruce. Looking forward to watching this thread.

Question: what kind of engine paint are you using? Very shinny and smooth as glass.

I used Duplicolor with ceramic. Everything was prepped properly, etched primed and baked (my wife loves me). I probably should have used the POR-15 stuff, but I didn't know about it at the time. Hopefully it will hold up well.

 

[Guest]

Nice work Mr. Bruce. BTW, what exactly is the benefit of using the 750 (years? 77- 80) oil pump gears. I take it you replaced both of them?

The 750 gears move more oil, which is helpful especially in modded motors. And yes, you need both the driven and drive gears or they won't mate up.

 

[80GS1000]

Which cams and how much lift are you getting? Are you planning on adjustable cam sprockets and a manual camchain tensioner?

I'm subscribing to this thread.

 

[Tarbash 27]

Who did your crank?

 

[Guest]

Which cams and how much lift are you getting? Are you planning on adjustable cam sprockets and a manual camchain tensioner?

I'm subscribing to this thread.

Who did your crank?

I haven't decided on which cams to go with. I guess I'd better decide pretty soon! Probably the Webcam #110 grind. I need to check my notes... Dan Rudduck recommended a cam once that sounded like just what I wanted.

Yes, I will be going with adjustable sprockets.

I would like a manual camchain adjuster, but I don't think they make them anymore? There was this guy in Utah that knew a guy that might have one sitting on the shelf..... oh yeah,... that's you, PJ!

There is an old broken-up ex-Kawasaki racer/builder that lives out here by me. He did the crank welding for me. He will probably be helping me with my frame bracing, too. He's an amazing welder (you should see his aluminum work). He'll also be looking over my shoulder when I do the degreeing.

 

[49er]

Bruce, did the early 1000's have a problem with clutch drag when they were cold. The 850's did and it was mainly caused by too much oil pumping into the clutch basket and not being able to exit it quickly enough. Suzuki fixed this by reducing the inflow diameter through the release rack. I did this mod to my engine, plus drilled some extra holes just inside the splined ring of the pressure plate. You may want to do this to your pressure plate if drag was an issue.
Nice looking project. Keep us drooling.

 

[80GS1000]

Yes, I will be going with adjustable sprockets.

I would like a manual camchain adjuster, but I don't think they make them anymore? There was this guy in Utah that knew a guy that might have one sitting on the shelf..... oh yeah,... that's you, PJ!

Doh! I'll give Jake a ring and see if he has any other GS1000 hop-up parts on his shelf.

 

[first timer]

Hey Bruce check this out.

http://gszone.biz/sprockets.html

I am pretty sure you can fit a gs1100 manual cam chain tensioner on a Gs1000.

i think they are all the same. Maybe check the part numbers. I am prety sure i have a gs1100 on mine

worse case pull your 1150's and see if it fits on the 1000 if so then the ape one fits.

BTW, awsome job so far.
can you tell me about your clutch basket. where did you get it did it have to be trimed down?

 

[Tarbash 27]

The gs1000 and gs1100 have the same part number for the cam chain tensioner. I will be putting that ape tensioner on my 1000 motor. I'm also going to use the ape tensioner guide.

 

[Guest]

Just give me an exuse to come up and help you!

 

[J_C]

Just give me an exuse to come up and help you!

I've got one for you to come down and help me



Looks awesome Bruce. Can't wait to see the chrome hardware that you showed me. Will look awesome against that black engine!

 

[Guest]

Bruce, did the early 1000's have a problem with clutch drag when they were cold. The 850's did and it was mainly caused by too much oil pumping into the clutch basket and not being able to exit it quickly enough. Suzuki fixed this by reducing the inflow diameter through the release rack. I did this mod to my engine, plus drilled some extra holes just inside the splined ring of the pressure plate. You may want to do this to your pressure plate if drag was an issue.
Nice looking project. Keep us drooling.

I wasn't aware of this problem. I've never had a problem with my Skunk. I looked at the release rack and there is no hole going through it.

 

[49er]

I wasn't aware of this problem. I've never had a problem with my Skunk. I looked at the release rack and there is no hole going through it.

Sorry for the confusion. On doing more research, it appears most of the complaints of clutch drag come from early 750 & 850 owners.

How does the 1000 clutch get it's oil feed? I know that the basket is of a larger size/design than the 850's but it's oil feed is obviously different too.
Also, basket rattle seems common with the 1000's but not so on the 850's!