'81 GS1000G Sensible Mods

[detorn]

As I have mentioned in another post, I have recently purchased an 81 1000 G. It was pretty well kept, but had some silly (IMHO) mods done to it. This thread will journal that rehab, along with some more sensible mods that I plan on doing along the way.

First on the agenda is replacing the stator and doing the Honda R/R upgrade. While I'm doing this I am going to attempt to address an oil leak. The leak is coming from the pan area. The area is covered with some type of epoxy, so I do not have a visual of the problem. I am hoping that it is just a bad gasket, I have ordered a new one. I have also ordered the hex bolt kit from Z-1. That'll fall under the sensible upgrade heading. Finally, under the why not while you're there category, I have ordered a new oil filter, o-ring, and spark plugs.

Today and tomorrow I will be doing the break down.

Upcoming to dos (not in order):
Check valve clearances - have to triage spending on gasket or this would be happening now.
Change all electrical connections - I don't like or trust the stock ones.
Find original airbox
Return to stock jetting - probably do a new cleaning and o-ring make over when I reach this point
figure out what the PO did to the pipes - removed baffles?
retune carbs
Replace Break lines -
New handle grips
New handle bars -

This should take the whole summer to finish at which point I'll bring the entire maintenance schedule up to date.

I am also going to keep a log of time and money spent on this project.

Cycleworld Cherry hill
GASKET,OIL PAN $9.90
O RING $4.41
total 15.31
Z-1
Plugs
filter
bolts
stator gasket
total 47.65
Auto Zone
Battery (think I'm going to return this) 50.00
Bike 600.00
insurance 75.
Tags & Title 140

Total: $927.96
Time: 0000 Hours

 

[Graham]

Have fun. Doing the same stuff and more to restore my old GS1100GL.

 

[detorn]

After a birthday and a couple days recovering from that, and waiting for deliveries I have some updates.


Parts from bottom left. Bob Barr's o-ring kit, Stator gasket, Z1 bolt kit, plugs and oil filter, duanage stator and R/R.

Got the pipes and battery box off the bike. Was making good progress till I hit monday and had some medical problems.

need to pick up anti-seize, 4 quarts of oil, carb dip. Sunday and Monday are going to be really nice here. Going to try to have it running again by then. And continue the work while the bike is in a running condition.

New cost:
o-ring kit 25.10
mics parts - 50.00

Total 1,003.06
Hours - 0002. hours

 

[detorn]

New R/R is installed. While dealing with and oil leak I found metal chunks in the oil pan, that issue is being addressed here.

I will not be able to reassemble until I figure out what that metal came from. So no riding for me for a while. Gunning to have it back up and running by May 6th, we will have to see if the weather cooperates with me.

Getting the stator cover off was a little more work than I thought it would be, I got help with that here.

One of the sprockets in there was loose. The pin that holds it all together came off with the cover. I'll start a thread on that when I start putting it back together. I need to rethink my whole plan of attack. I'm not sure if I should just do a whole engine rebuild while I have it this taken apart. What would you do?

Thank to duaneage for turning me on to Harbor Freight. I haven't been that excited in a store since I was a kid walking into Toys R Us.

Impact Driver & mics tools $20

Total 1,023.06
Hours - 0005. hours

 

[Rover]

Fun project,do you something to ride while your bike is down?

 

[detorn]

I do not, I got this one cause it was a good price... Looks like I may have gotten what I paid for. Not really sure how to proceed.

 

[Tom R]

Why so much for the oring kit?
Old bikes are always like that - everytime you take one apart you find five problems you didn't even know existed in parts you've never given a minute of thought. They'll nickle and dime you to death. But at least you like putting a wrench to them - right?

 

[detorn]

I got the intake oring and SS bolts along with the orings...

I do actually enjoy doing the work, its my lack of knowledge and money that upset me...lol

 

[Steve]

Why so much for the oring kit?

What is so expensive about $4.41 for an o-ring kit? :-k

Try pricing the OEM o-rings, instead.

My question about expenses is "how much is registration in PA?"
You have "tags and title 140".
Here in oHIo, the title is $11 or 12, that leaves about ... $130 for tags???

I thought the $43 in oHIo was bad.

.

 

[detorn]

What is so expensive about $4.41 for an o-ring kit? :-k

Try pricing the OEM o-rings, instead.


You have "tags and title 140".
.

the 4.41 was for the oil filter oring... the bob barr collector kit was 25, I think thats what he was talking about.

As far as the T&T, I was shocked as well. I don't remember paying that much the last time, but my memory is not good, so who knows.

 

[ddaniels]

Nice looking bike you have there. Same model and color as mine. Good luck finding what caused the metal chunks.

 

[850 Combat]

I hope you can get the airbox at a reasonable price.

 

[TheCafeKid]

I may have an airbox to sell cheap. Needs new rubber on both sides though..

Also, you have a pic of the metal chunks you found?? Could be spring bits from the starter clutch.. They are somewhat notorious for self destructing. Ask me how I know

 

[TheCafeKid]

What is so expensive about $4.41 for an o-ring kit? :-k

Try pricing the OEM o-rings, instead.

My question about expenses is "how much is registration in PA?"
You have "tags and title 140".
Here in oHIo, the title is $11 or 12, that leaves about ... $130 for tags???

I thought the $43 in oHIo was bad.

.

Better question is: When's the last time YOU registered a vehicle in Ohio??

Title will cost 7.5% (maybe its 7%) now of the purchase price, plus fees.
Tags are around $60ish..

The title is what gets ya.. Unless of course your seller doesnt mind if YOU fill the selling price in... but that's not exactly on the up and up either

 

[detorn]

I may have an airbox to sell cheap. Needs new rubber on both sides though..

Also, you have a pic of the metal chunks you found?? Could be spring bits from the starter clutch.. They are somewhat notorious for self destructing. Ask me how I know

I think I'm going to hold off on doing the restore the way I wanted with the original airbox and all because that loot is now going to have to go into fixing whatever it is that blasted apart. Job interview tomorrow though, so that could change too.

pics of shrapnel below

 

[TheCafeKid]

huh... You pulled the stator cover off yet?? Looks like it COULD be possibly part of the rotor/starter clutch...but then again it looks like part of the cases too (the light coloured piece anyway)

 

[detorn]

huh... You pulled the stator cover off yet?? Looks like it COULD be possibly part of the rotor/starter clutch...but then again it looks like part of the cases too (the light coloured piece anyway)

I have pulled the stator cover. the only thing that was odd in there was the pin came off with the cover, but that clymer book said that happens. Nothing looked mangled or disrupted. Also, the darker pieces look more bronze or brass irl, flickr downsizing them makes them appear darker.

 

[TheCafeKid]

I have pulled the stator cover. the only thing that was odd in there was the pin came off with the cover, but that clymer book said that happens. Nothing looked mangled or disrupted. Also, the darker pieces look more bronze or brass irl, flickr downsizing them makes them appear darker.

hrmm.. Dunno anything made of brass in there...

 

[detorn]

Well I bought that nice bolt kit from Z-1, so now is as good as time as any to start breaking it down till I find the culprit switching out the bolts in the mean time. then I can cry for help again as I am rebuilding. lol

Quick question for all, as of right now the tank still has gas in it. Would it be better to drain it or leave it in there? Also, since the oil is now out, do I have to worry about clutch plates or anything else getting messed up while its dry? between getting loot for parts then waiting for them to arrive, I'm thinking this is going to take some time. What are the best storing options?

 

[7981GS]

Some of the pieces in your post #15 look EXACTLY like they are parts of
number 3 in this picture. And the larger black plastic pieces are part of number 11.

I know from personal experience because I found them in one of my engines.

I found another engine to build.


Daniel