The '82 GS1200G project

[7981GS]

I have spent quite a bit of time and some money gathering all of the parts.
I finally have the majority of them.

Starting with this:

Started cleaning up the tired engine yesterday. It wasn't pretty!:

After several scrubbing and cleanings:

Continued...

 

[7981GS]

Today, I tore it apart and started to hang the pistons.
She looked to be in much better condition inside.

Old stock 72mm piston next to new 76mm forged slug:

Old 1100 cylinder next to sleeved 1000 cylinder:

One piston hung so far:

Daniel

 

[Ranger]

Looks like lots of rusted bolt heads or nuts.

 

[srsupertrap]

That is going to be a torque monster with those 76mm slugs

 

[Nessism]

Torque monster for sure. I suggest you do that ignition delay mod to save the starter clutch.

 

[7981GS]

Looks like lots of rusted bolt heads or nuts.

I got new Grade 10.9 knurled/shoulder lock nuts to replace those today.

Daniel

 

[7981GS]

I had the old (6 Y.O.) tires dismounted off of the rims today also so that I can paint them before mounting the new shoes.

Daniel

 

[NOS]

I had the old (6 Y.O.) tires dismounted off of the rims today also so that I can paint them before mounting the new shoes.

Daniel

Why are you attacking me in other threads?

 

[gsryder]

If you can get away with it your dishwasher will be your friend for cleaning up those cases, cylinders, valve cover, etc. Get the big stuff off first then run it for a cycle they come out spotless........as long as the wife or significant other doesnt mind!!!!

 

[FreshStart]

I see a rear hub repair in your future.

Great idea though.... maybe i need some of this.

 

[7981GS]

After waiting 2 weeks for the custom-made base copper gasket to arrive,
They got my order backwards and sent an 83mm I.D. base gasket for a 4-valve engine!!!!

I hate setbacks!!!!!!!


Daniel

 

[7981GS]

They pushed other work out of the way and made the gasket yesterday and paid to over-night it to me so that I could get back to work.

Not real happy seeing Daylight here:
(I filled the gap between the egg-shaped O-ring with Ultra Black and let it set up.)

Covered the crankcase so as to not loose the cir-clips that retain the piston pins. The green assembly lube on the pins is Caterpillar Cam Follower Lube.

All four pistons hung and ready to install:

Finished honing the cylinder, cleaned the brake cleaner out, oiled the cylinders, wiped until white paper towels came out white, then re-oiled with straight 50W oil and assembly lube at the chamfer.

Installing:

My riding buddy helped:

The stealth cylinder marked 997 (v v v) belying the 1200 inside.

Waiting on the cylinder head tomorrow:

Daniel

 

[ArtByScars]

hey I know that shed! cant wait to see this thing fire up!

 

[tkent02]

Where did those pistons come from? They look to be much higher compression? How will the rest of the engine be done?
Sounds like fun.

 

[7981GS]

Where did those pistons come from? They look to be much higher compression? How will the rest of the engine be done?
Sounds like fun.

The pistons are an older set from http://www.mtceng.com/.
They no longer make pistons/kits for the 2-valve Suzuki's.
Those are 10.50:1 forged units using custom made Cometic copper base and head gaskets of my dimensions.
34CV carbs, stock 1100G camshafts, slightly ported '81-'82 (I forget )
1100 head, stock-type after-market exhaust, perhaps even stock air-box.
(still undecided) And a large oil-cooler.

The idea was to make an inexpensive 1200 touring GS for 2-up riding.


Daniel

 

[Rudeman]

Those MTC pistons hould be durable. Too bad Wiseco quit making their 1176 kits.

 

[Guest]

That base gasket is BS.

 

[Nessism]

That base gasket is BS.

It's for a chain drive 8v 1000. Think I would have used a stock Suzuki base gasket and opened it up with an exacto and/or a sanding wheel to expand the bore holes until it fit those big bore sleeves.

 

[7981GS]

Between fighting with getting the correct parts for the '63 Panhead that I am building for someone else,
I finally got some time to get back to one of my projects.

Extracted two broken exhaust bolts a couple of days ago:

Left-hand drill bit to the rescue!

Re-tapped all of the bolt holes. Ordered new HD studs.

Stock exhaust port...

Raised the roof, cleaned up the short side radius and matched the exhaust pipe I.D.for a little better flow...

Installed copper head gasket...

Finished bolting up the head and torqued down. Installed cams and torqued caps...

Lightly painted some of the engine with VHT Hi-Temp. (900 Degree) rotor and drum Cast Aluminum Paint...

Hoping to get 500 miles on it before the WS Rally at Renobruce's in a few weeks. ray:
Wish me luck!!!


Daniel

 

[7981GS]

No interest in this? It must be a normal thing to do with these bikes...
Politics, seat cover styles, carb problems, stock builds, rat bikes, muffins, BMW's, Kawasaki's and Harley's it is then.

Daniel