GS1000 Base Gasket Replace. w/ Pics

[Billyboy]

Cleaned up the combustion chambers yesterday. Not perfect, but pretty good, I think.

[80GS1000]

What'd you use to decarbonize?

[Billyboy]

What'd you use to decarbonize?

On the valves: sharpened screwdriver. Used as a chisel.
Chamber: VERY careful use of same [-o<, brass brush, steel wool.

I think a brass wire weel on a dremmel would save a lot of time.

[Big T]

*AHEM*!!

Hi there. I'm Canadian.:-D

See, even Ozzies and Kiwis dis the Canadians.

Looking good so far. Are you about ready to start reassembly?

BTW, I used the 4 hose clamp method on my pistons to reinstall the cylinder block. Easy for a solo operation.

[Billyboy]

See, even Ozzies and Kiwis dis the Canadians.

Looking good so far. Are you about ready to start reassembly?

BTW, I used the 4 hose clamp method on my pistons to reinstall the cylinder block. Easy for a solo operation.

I think I'm ready.

Thanks for the tip.:-D

[Nessism]

Combustion chamber looks great. Good job.

How long ago since the intake boot O-rings were changed? If more than 5 years or so, now is a good time.

[paintmann111]

Man, this whole thing makes me want to tear into the GS650 and fix all the little problems. Only thing is parts and me being 550 miles away.

[Billyboy]

Combustion chamber looks great. Good job.

How long ago since the intake boot O-rings were changed? If more than 5 years or so, now is a good time.

I've got new o-rings somewhere. I've just got to find them and install.

[Smokinapankake]

Billy Boy,

Just surfed through this thread and let me say thanks so much for the great photos and commentary. I, too, am in the proces of complete and total overhaul of my GS1000SZ motor (16v). You are very lucky to have not had any trouble with your base gasket. I suspect mine was the original and let me tell you it's been a bloody nightmare to get cleaned off.
I'm using Dupli-Color engine paint with ceramic, and so far so good. Of course, the motor isn't back together yet, but it seems durable.

I stripped down to the cases and cleaned them in a solvent tank, followed by a high temp industrial parts washer. Repeated the cycle 3 or 4 times and my cases, jugs, and head all came out spotless. Of course I, too, coated the guts with WD-40 to prevent corrosion. As far as cleaning the pistons, I let them soak in seafoam for a few nights and they cleaned up real nice. Still need to get after the combustion chamber but it's too cold in my garage and I don't think mama would appreciate me dripping black goo all over the living room carpet....

Kudos to you for a job that appears to be well doing!!

[Billyboy]

Thanks, Smoke!
Good luck with your big Kat.

After careful consideration, I'd decided not to paint the jugs. It looks too good in stock form, and I don't think I could prep it well enough to make it stick.

Found my o-rings. Little grease to install, or dry?

[Billyboy]

I couldn't find anything in the manual about installing new intake o-rings, so I decided on dry.

Stupid photobucket won't let me upload one pic.
It's of the head with two boots installed and two not.

Here's the two remaining boots and o-rings. The boots are still very pliant and flexable. If not you better replace them.


Then after I got them on I had a stroke of genious: Loosen the vacuum ports NOW rather than discover them to be seized later.:-D Of course, my beloved GS didn't let me down. They came loose after applying only moderate force.

[psyguy]

Found my o-rings. Little grease to install, or dry?

i'd use a little high-temp grease, for longevity and easier removal down the line

[Smokinapankake]

Ditto on the vacuum port bolts....

[Billyboy]

How high is high temp?
I've got some continous 205C grease. Will that do?

[psyguy]

How high is high temp?
I've got some continous 205C grease. Will that do?

huh, not really an expert on that... the one i use just says "withstands extremely high temperatures" LOL!
i think you should be all right though. the idea is that it shouldn't run off or burn readily and your application is not critical anyway (such as brake calippers for example) so i'd use it