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Budget GS1000S rebuild. Not!!

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Guest

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I purchased my GS over a year ago with the intention of a 'budget' resto. It had a smack in the rear which bent the seat subframe slightly and broke the tailight. The previous owner is a mate and had used and abused it for many years.I decided very early on that I would do all the work myself, keeping costs down. I hold this forum and ebay responsible for the money I have spent since!!:rolleyes: My plan also was to black everything out , inspired by the gorgeous products from Sanctuary in Japan. (I hadn't yet seen Larry Pearson's masterpiece)
Firstoff, the engine came out of frame, GSXR rearsets fitted and while the frame is this 'empty', it makes sense to powdercoat, doesn't it? Rear shocks purchased. Then, of course the nuts and bolts needed to be zinc coated.
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While I'm up to my armpits in chassis bits, the engine is off to GegT for a freshen up (130,000km), and while its pulled down, I had it soda blasted along with the tinwork.
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All good so far- engine in good nick, so replaced camchain, bores got a light hone, repaired crankcase where some butcher had put a too long bolt through in the lower case mount and then araldited to curb resulting oil leak! Greg dialled cams, and after I painted engine black using epoxy 2pak, re assembled.
 
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Oops! Forgot- I had also made a fibreglass seat base as mine was darn rotten. Thanks, Kev for loaning me your racebike base to mold. By now, I'm becoming a regular on ebay, a set of Progressive springs and a set of Mike's modulators are on their way. I bought a set of '85 GSXR wheels to fit better tyres followed by K5 GSXR 750 320mm discs, calipers and mastercyl. Greg dummied up front end and we couldn't get the discs and calipers to work (not enough offset). So its check out that excellent Metalgear site resulting in a set of ZXR discs quickly on their way from the States. Bingo! Greg made up a set of adapters, did a bit of machining of the speedo drive and we soon have a front end that should pull stoppies!!
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A blown budget? Welcome to the ever expanding club.

Great progress so far. That brake set-up looks track worthy.
 
"S" and "Budget" don't get along well! I'm not sure what the S originally stood for, but now it stands for $.

Good luck with your project, looks like your off to a good start.

I am off to see what this Sanctuary in Japan is that you mentioned!
 
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[QUOTE. So its check out that excellent Metalgear site resulting in a set of ZXR discs quickly on their way from the States. [/QUOTE]
???? Far as i knew there here in OZ about 15klms away from me...... http://www.metalgear.com.au/
 
sharpy said:
[QUOTE. So its check out that excellent Metalgear site resulting in a set of ZXR discs quickly on their way from the States.
Click to expand...
???? Far as i knew there here in OZ about 15klms away from me...... http://www.metalgear.com.au/[/QUOTE]

Quite correct Sharpy...But if you want to cross check which discs have the same hole size and bolt pattern but different offset...it's the best place to look. Then to ebay for a good set of what you've decided on.

You'll be amused to know that the NZ agent for Metalgear is exclusive - no internet sales to NZ from Oz - and charge like a wounded bull.
When i wanted new rotors for the racebike, the owner was still working in OZ and we saved quite a bit even including 2 lots of postage.
If they're close to you and you'd like some petty cash, you could look at acting as an agent for NZ customers.....
 
If its the Motozone webpage i cant even see a GS1000 disc. Friggn hard to navigate. Retail here is 129.95 for a metalgear LF disc.
 
sharpy said:
If its the Motozone webpage i cant even see a GS1000 disc. Friggn hard to navigate. Retail here is 129.95 for a metalgear LF disc.
Click to expand...

Yeah, that seems to be std retail for most common discs - but here it's $nz 250/260....and given we have a pretty good exchange rate at present and have had for a while, it's daylight robbery IMO. agent is Northern accessories I think.
I actually used CB1000F rotors on homemade solid centers for the racebike. Floaters weren't allowed but we've since changed to match the Oz regs.
 
Hi Sharpy, yep, should have mentioned I used Metalgear to find discs with correct offset and then purchased 2nd hand on ebay. The US is such a huge market that we can't hope to get a deal here to match. And I am on a budget after all! My 'S' is fitted with the 'down under' VM30SS slide carbs which I believe were only sent to Australasia and Canada?.Of course, one of the air bleed screws was broken off in the body of the carb, so back to Gregs for some delicate jiggling, and out she comes! Back onto ebay, and sourced a set of generic Mikuni screws from Sirius Motosports- a perfect fit! These Suzukis are great the way they use common parts across so many models! I've played around with mainly Hondas thru the years and you just don't get the interchangability. Right! Time for the engine to be refitted to frame- but which way? I took the engine out by myself the conventional way, but wasn't confident I could get it back in without wrecking the paintwork, both on the engine and frame. So it was a no-brainer really, drop the frame over the engine!
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Perfect!! A bit of cardboard wrapped around frame and voila!! Engine in again. It's amazing how getting a major bit fitted reactivates the enthusiasm.
 
Think those carbs where on the Sth Africian ones aswell. Never heard canada got them. Same carbs as the Katana 6 hr special i think. My bikes 1st owner sold the carbs as he put 33MM smmothbores on mine, Then my "Mate" wanted them more than me when i let him stay at my place. Has 29 smoothies on now but have 2 sets of 33's waiting in the cupboard What paint is that on the engine, its a nice satin finish.
 
It's a Resene auto product called Durapox. Actually an etch primer but can be used by itself without a topcoat. Hard as hell and used on our Kiwi Americas cup cat for all the good it did them.:cry:
 
sharpy said:
Think those carbs where on the Sth Africian ones aswell. Never heard canada got them. Same carbs as the Katana 6 hr special i think. My bikes 1st owner sold the carbs as he put 33MM smmothbores on mine, Then my "Mate" wanted them more than me when i let him stay at my place. Has 29 smoothies on now but have 2 sets of 33's waiting in the cupboard What paint is that on the engine, its a nice satin finish.
Click to expand...
The VM 32's also came on the GS 1000 ST in Europe.
I believe it's only the USA that got the CV carbs?
A picture of my GS 1000 ST with the GSXR wheels to encourage you to finish the bike;)
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Well, had quite a satisfying day in the garage today. Got the new rear sprocket fitted for my 530 chain conversion. Wheel fitted and rear brake bled. Will have to check centering of wheel and line up sprockets. Hoping I can space front one to line up without having to machine rear hub.

ar.

Then fitted gear lever rod which has been shortened. (Ex GSXR1100)




Then it was onto the front end, fitted new braided lines from UK and bled them.



Spent a bit of time on Spendbay last night and organised a K&N filter, set of plugs, X Ring chain and chain tool for a 'bargain' price.:rolleyes:

Thanks for the encouragement, John, your bikes always inspire me!!
 
There are a couple of bits I need to complete my project. Does anyone have an aircleaner top (for the compartment where the filter lives)? Also need a fuse box cover and a chainguard.
Also have been thinking about the front fork tops- anyone know of any fork tops without the air caps that will screw into the standard forks? Thanks guys. Adrian
 
Talk to Kev at Ruapuna sat, you are coming ? In the pile of spare bits for his GS's there are two airboxes - complete with lids...
 
Great work there. There's not much more satisfying than restoring/renovating/resurrecting an old GS. ;-)
 
Brilliant job. I wish I had that sort of skill...

Keep up the good work.

Cheers
Muz
 
I wish I had that sort of skill...
Click to expand...
Ah, but YOU DO. ;) You simply have to give the Engineer that lurks inside every Y-chromosome bearing individual (and a few XX sorts as well) a break! This means finding something that stretches your mechanical envelope. For some it will be changing the spark-plugs. For others it will be welding up and machining a whole new swingarm, or installing/tuning a supercharger kit, or building a motorcycle around 18 lawnmower heads grafted onto a single crankshaft.

But then, no matter the challenge you have set yourself, you find that your skill-set will develop. True, some have more natural talent than others, but this is just one of life's injustices that we have to live with. The main thing is to nurture the Engineer Within. :cool:
 
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