Finally took the plunge.

[Matchless]

I did a rebuild of a '79 GS1000S and did what you are doing.Keep going the way you have so far and you will end up with a "new" bike.I replaced ALL the bolts with stainless(cover bolts etc) or zinc plated high tensile for anything else(engine mounts,calliper mounts etc).I would also replace all the bullet connectors on your harness as well.They are no where as reliable as spade connectors.I had my wheels polished and repainted with a two pack and they came up beautiful.Every part I had ANY concerns with,I replaced with NEW.It might cost a bit but you will be rewarded with reliability.You are doing well so far.Keep up the high standard.Cheers,Simon.

Simon,
Thanks for the reply. I am also replacing as many bolts as the eye can see with stainless steel. Also replacing all the bearings and seals. The wheels are my next 'larger' step. Once the rotors, bearings and tyres are off I will see how to go about it as they are of cosmetic importance as well.

 

[Guest]

Matchless old mate,be careful of stainless for any "structural" bolts as they are not very "tensile".Be sure to use antisieze on stainless as well or the threads can bind or grow into alloy.Just a slight smear will do.You are right about your wheels,if they are done well,they add to the appearance untold.I'll follow your progress with much interest as you seem to be going about things the same way that I do.That is , do it properly with as many new parts as possible.The long term benefits will be your reward.I can hop on my old girl knowing she will go and go and go,and I know she'll get me home.I'm off on a ride in 3 months that will see over 8000 km and the only prep I'll do is oil and filter.Cheers,Simon.

 

[Matchless]

Matchless old mate,be careful of stainless for any "structural" bolts as they are not very "tensile".Be sure to use antisieze on stainless as well or the threads can bind or grow into alloy.Just a slight smear will do.You are right about your wheels,if they are done well,they add to the appearance untold.I'll follow your progress with much interest as you seem to be going about things the same way that I do.That is , do it properly with as many new parts as possible.The long term benefits will be your reward.I can hop on my old girl knowing she will go and go and go,and I know she'll get me home.I'm off on a ride in 3 months that will see over 8000 km and the only prep I'll do is oil and filter.Cheers,Simon.

Thanks for the S/S mention. I am using #7 Stainless Steel bolts and only for those with the standard thread. The high tensile bolts, Suzuki #9 I am re-using where possible, but thanks for the heads up on that.
I have just ordered new fork seals although mine are still perfect. Thought I might as well replace while the forks are out.
I appreciate all input! And any tips are welcome.

 

[Guest]

Matchless old mate,here's my old girl after completing what you have begun.Like I said,if you do it right,you'll have a faithful old girl that will give you no grief(except what all the old girls (both types)give us).As I was doing her up (she was a dirty girl when I found her),I replaced/refurbished EVERYTHING and now have a rare and reliable ride.Worth every cent I spe

nt.Cheers,Simon.

 

[Guest]

Old mate the metal polisher did my wheels.Acid cleaned,painted and polished.Couldn't be happier.All up $400 for both wheels.Cheers,Simon.

 

[Johno]

Contacts in Australia

Contacts in Australia

Simon,

I'm looking to do a similar refurbishment of my 1981 GS1000G.

I live in Sydney. Where do you suggest I can source replacement nuts and bolts. I have cleaned a number with rust but the plating has been damaged and they will rust again.

Your polishing also looks great.

Did you get it done in Brisbane?

Any advice would be welcome

 

[Guest]

Johno,I got all the bolts,stainless and zinc plated high tensile from the local"nut and bolt" dude.The polishing was done by a lad in Cairns.He did my carbs as well.Money well spent I reckon.Cheers,Simon.

 

[Johno]

Thanks Simon

Thanks Simon

Johno,I got all the bolts,stainless and zinc plated high tensile from the local"nut and bolt" dude.The polishing was done by a lad in Cairns.He did my carbs as well.Money well spent I reckon.Cheers,Simon.


Thanks Simon.

Much appreciated

 

[Matchless]

Matchless old mate,here's my old girl after completing what you have begun.Like I said,if you do it right,you'll have a faithful old girl that will give you no grief(except what all the old girls (both types)give us).As I was doing her up (she was a dirty girl when I found her),I replaced/refurbished EVERYTHING and now have a rare and reliable ride.Worth every cent I spent.Cheers,Simon.

Whaw, Simon, you actually did "everything". Its as smart as one can get it!! I do not think I will have mine like that soon. I will do the bolt on things later once the bike is up and running again and I need to do it over a longer period, otherwise my wife will not see this as a hobby!

Excellent!!

 

[Matchless]

Today finished the steering stem bearing replacement and reinstalled the revamped wiring harness as well as the coil relay and horn relay modifications as well as wiring for the 12 Volt assessory plug at the front.

 

[Guest]

My plan was to take a year or two to do mine as well,but once I started ,I just couldn't help myself.I couldn't put new and old back together because the NEW made the OLD look just sooooo old.I guess I've got the GS addiction.Good thing I'm not into chemicals.Cheers,Simon.

 

[Matchless]

OK, frame up to now has swingarm back and steering stem on with new bearings. Wire harness is fitted and reconditioned. Forks are apart and I am still awaiting delivery of the fork seals from the USA. Set of new cables have just arrived. New wheel bearings are also at hand and back tyre still to be pulled to allow rim to be polished and painted. Have been spending time cleaning and painting small items such as gauge brackets and cover. Final drive casing and fork polishing is in progress. No serious progress worth any pictures until fork is back on. I have also replaced all fork pinch bolts with stainless steel.
Received confirmation today from Athena on the use of the latest spec headgasket and I may start assembling top end on motor next week. Will post some pictures then.
I did the coil modification and put together a pictorial on the method I used as well as another on the forks to date, just need to complete when the seals go in. These are available if anyone wants it, just shoot me a PM.

 

[Matchless]

I finally sat down and did my coil relay modification when overhauling the harness and while the bike (GS1000G 1980) was apart. Here is a link to the exact step by step procedure and some photos with the diagram that I followed a few weeks back. http://www.mediafire.com/?xhvz02jxzuv

 

[Nessism]

Enjoying this thread but need more photos please!

 

[Matchless]

Thanks for reminding me! I will have to make work of it tomorrow when I tidy up my workshop. We have had some poor weather here and my progress has slowed down a bit.
If only those #!%*! fork seals will arrive then I can get the forks set up and back in and some pictures showing noticeable progress.

 

[posplayr]

Matchless

Matchless

Thanks for the details on the coil modification. TMy GS1100ED now has all new harness and handlebar switches but the ignition relay modification is a nice modification to insure good ignition.

The GS750 should get the same treatment.

Gotta clean the garage up first though.

Posplayr

 

[Matchless]

Glad you can use it. Your project looks outstanding and the amount of work you put into it was staggering. You can really be proud of your bike!

 

[Matchless]

Some small progress made. Fork seals have arrived and will assemble later this week.


Parts laid out while cleaning garage, new cables, polished forks, painting disks and gauge cluster cover. Awaiting rechrome of front emblem and headlight ring. Wheels also in to polishers and then getting new bearings.

 

[Guest]

Very impressive.That's how they all should be done(that's just me though--and I AM a bit weird).Cheers,Simon.

 

[Flaggo60]

Matchless,
Just noticed the polishing job on the final drive housing-fabulous. Do you plan on coating the bare metal with a clear coat?