The tossed 78 GS1000 rebuild thread.

[IanC]

Just the camera angle. Luckily everything on the frame was straight.

 

[IanC]

Just a quick update with the seat test fit in black and some tank pics requested by dad.

 

[Suzuki mad]

Just the camera angle. Luckily everything on the frame was straight.

Phew.

Are you going to strip the parts out of the forks and keep the stantions for spares as it's only the tubes that are bent? The air valve part that screws into the tube at the top of the leg is now unobtainable here in the UK.

 

[IanC]

With two GS's in the family everything that can be saved will most likely get hoarded, just in case.

 

[Chris]

Weekly progress report is due!

Weekly progress report is due!

OK,it's been a week. Tell us what's new with the bike. Remember, you have to get cracking so we can ride together this summer!

 

[IanC]

Progress is still being made. I've decided powder coating might be out of the budget so the frame will get cleaned, scuffed and painted. Maybe next season I'll do the powder coating. Time restraints and all. In the mean time I've been working on stuff like this:

The old generator casing as we had just replaced it with new. Since I have one I decided to try cleaning it up to just reuse it.

Coming along but taking my time with it since it's a big job. It was pretty nasty. Still working on polishing other parts. Been dropping hints to Colin I want a dremel for my up-coming birthday so I can get the smaller parts too. I've had two of them but they both grew legs as tools have a habit of doing.

 

[IanC]

Wondered if I could get the points cover even better looking. Yup.

Started on the carb caps and bowls.

 

[Chris]

Those covers are sure shining up nicely. I think if you look in my garage on the shelves by the compressor you should see my Dremel tool. If not there it's in one of the roll around tool chests. If you can find it feel free to use it.

On an unrelated note the used fairing parts for the bimmer should be showing up this week. Pick the best parts from the pile and let's get the parts to the bodyshop to get started on the repair and paintwork.

I was looking at the Bikebandit site and looking at the IPBs for your bike I noticed that they show the tank for your bike still available from Suzuki which surprised me. I was wondering if the tank available from Suzuki would have the depressions for the stripes on the side or if it's a superseded part number that would be common to all chain drive GS1000's.

Have the new wheels and forks shown up yet?

 

[TheCafeKid]

THe "skunk" tank is no long available thru suzuki. The part number has been superceeded and the new part is the 80 and up tank, no stripe depression..

 

[IanC]

Bummer. That would have been nice. Finished the generator casing today. Hard to believe this is the same one we felt needed to be replaced. Still not perfect as a PO had scuffed it up. Looks like a garage tip over or something. Nothing major but some deep gouges. I'll still want to replace it again at some point but once again, budget/time issues said to reuse what I have laying around.

 

[IanC]

One last bit done before I called it a night.

 

[Chris]

Thanks for the info TCKid. I suspected that might be the case since I had tried a couple of years ago to source a new tank for my GS1000S and was told Suzuki had discontinued them.

Ian, those covers are looking great! You'll have to do mine!

(Just kidding! Come over to the garage this summer when I get back to the US and we'll polish together while I supply the beer and brats. We'll just tell your Mom it's "bonding" time.)

 

[IanC]

Project still going. Forks, wire wheels, gaskets, headlight and bucket are all coming in the mail. Think dad is getting some SS braided brake hoses made up for me. I degreased, washed, scuffed and primed the frame. Tomorrow I'll scuff it and wash it again before spraying it. Started cleaning up other random parts and painting them. Everything possible will be re-assembled with stainless hardware if not (axles, engine mounts, etc) the heads will be polished, installed then cleared coated with nail polish or modeling paint. I was pretty pleased with the polishing job I managed with a drill mounted polishing wheel but a co-worker said to bring them to him and he'd put them on a bench polisher so everything is boxed up and going to work with me tomorrow. Once the wheels are here I'll be unlacing them and all that will be going to him for polishing as well as the forks to polish the fork legs. I'm watching an 1100 swinger and as long as it stays in my budget I'll be picking it up too just can't decide on polishing it, painting it or leaving it be. Got outbid on the V&H exhaust so that's a bummer. Hopefully someone here gave it a good home. I'll be saving my pennies to add one as a finishing touch. Still no luck on a tank, taking it to have a good shop see if they can cut it open, fix it and weld it shut.

So far required parts list remaining is:
-Headlight mounting ears (Update, parts incoming)
-Lock set (somehow seat lock failed in crash, ignition switch housing broken on bottom)
-Fuel tank (Update, being repaired)
-Tail housing (mine might be fixable but it's cracked)
That's all I can think of that I need to find used unless someone has some nice mirrors. You can still buy them new from Suzuki but they are spendy. Everything else I need is just odds and ends I'm replacing while I'm in there.

 

[IanC]

Quick update. Bought an 1100 swingarm so that'll be coming soon. Now to decide whether to paint, polish or leave it.

Frame drying.

Headlight mounting ear. The other is bent so either I have to find one of fix it.

Re-assembly starts soon!

 

[IanC]

Body parts on the frame to get an idea of looks.

Electronics panel all cleaned up and mounted.

Also re-wrapped the wiring harness and picked up a bunch of stainless bits and pieces. Gotta play the waiting game on parts now.

EDIT: I also found someone who can fix the tank so I'm pretty happy about that.

 

[Chris]

brake lines

brake lines

Ian,

I boxed up your brake lines and will cart them over to the mailroom tomorrow. You should have them in a week or so. I hope the basic stainless braided lines and blue anodized parts such as the banjo fittings don't bother you. Had I known you were going for the total black out look I'd have gotten black lines and fittings. Sorry.

I like that the bike is starting to come back together and like the work you're doing, especially on the electrical panel. You sure are doing a nice job with our formerly orphan GS1000 refugee. This summer when we head north we should make it up to New York to show the former owner what became of his lost child. I think he'd like to see it.

Dad

 

[IanC]

Thanks dad. Not really total black out. I think the lines will look good. There will be lot's of black, a bit of white and lots of shiny. Oh and a little blue. Planning on an Earl's cooler so I'll try and get blue fittings for that and they'll both be good contrast.

 

[BassCliff]

Hi Mr. IanC,

Excellent progress. I recently went through a similar procedure rebuilding my bike after my crash. Luckily, my forks were not bent. I didn't take the engine out, but I took everything off except the engine in order to replace and repair the damage and perform other maintenance. I wish you luck and hope you have fun. I'm looking forward to your completed project. Nice work.


Thank you for your indulgence,

BassCliff

 

[IanC]

Not much to update. While I've been waiting on parts I've been polishing bits and adjusted my valves. Thanks Steve for the handy spreadsheet, Cliff for his excellent site and dad for the loan of the tool and voice of experience. I snapped some pics of the new parts that have made it in but my camera batteries died so I'll try to remember to pick some up tomorrow.

 

[IanC]

My coffee table currently:

No, I'm not married. How could you tell? I did manage to save my original speedo face and internals. Dropped them into an 85mph shell I had. I didn't break the old shell open or mangle the trim ring, the crash did that. I don't know how my gauge face and insides survived but I'm not complaining.

New headlight and bucket. Sadly the trim ring has a ding. Oh well still got it fairly cheap.

New headlight mounting ears as one of mine was bent. Thanks dad!

1100 swinger I bought off of Eric_Banks32 here on the forums. Soon to be polished.

Also got my pan gasket in finally and the motor is back in the frame. I'll get a pic up soon.