A skunk in the works

[steveday41]

1978 Suzuki GS1000 E (Skunk)

Just found and read 29 pages on your GS1000 E restore. I have been restoring my 1978 GS1000 E for the last year and a half. I got it where I could ride it last September and have been doing small cosmetics projects on it since then. I learned quite a bit by everyone's posts. I will be doing the rear shocks by tearing them down as shown in your post. I also found a correct pattern seat cover that I will be installing soon. Post pictures when your done. The GSResources have been and will continue to be a great resource for all GS Suzuki owners. Keep posting tips and where to find hard to find parts.

My bikes.
1978 Suzuki GS1000 E (Skunk) riding and still polishing to showroom condition. Original, third and last owner of this bike (at least as long as I am alive).
1978 Suzuki GS1000 C next project.

[chuck hahn]

WIZARDS...Most bike shops and auto parts places carry it. Its great stuff. You start heavy and rub it into the metal till it almost disapears and then you let it dry..buff it off with a rag.

[SVSooke]

Just found and read 29 pages on your GS1000 E restore. I have been restoring my 1978 GS1000 E for the last year and a half. I got it where I could ride it last September and have been doing small cosmetics projects on it since then. I learned quite a bit by everyone's posts. I will be doing the rear shocks by tearing them down as shown in your post. I also found a correct pattern seat cover that I will be installing soon. Post pictures when your done. The GSResources have been and will continue to be a great resource for all GS Suzuki owners. Keep posting tips and where to find hard to find parts.

My bikes.
1978 Suzuki GS1000 E (Skunk) riding and still polishing to showroom condition. Original, third and last owner of this bike (at least as long as I am alive).
1978 Suzuki GS1000 C next project.

This bike is not originally a EC,just a C.Thanks to my friends here I'm adding all the good EC stuff like twin discs.Means I get to avoid some of the E stuff that IMO is not so great,self canceling signals come to mind.Get my preferred flat seat to.Really wish I'd thought of the Penelope name for this project.When Dale(rustybronco) used it for his 78 1000 project and I figured out the reference well it was a "what the heck" moment.A skunk that's not a skunk is exactly what this will be.With luck it will take a real expert to notice.Most of those are here anyway.

Bit of news on the build.Had my first seized bolt yesterday.Rear caliper holder bolt.Knew better but snapped it anywayNot flush so I'll see if I can get a nut welded on at work.Hope it work like I've heard here.Sorry no pics to POed at myselfPut air to the caliper and blew out 1 piston,Just grand.So apart comes the caliper,no problems with those Allens there TG.Tried air to both the fluid and bleeder holes.No joy.Desperate measures I took a pipe wrench to the top of the piston to break it free.That worked and didn't leave much of a scar.Bit of air and it popped up and almost hit my head!As soon as I get the bolt out I'm painting the master and caliper with caliper paint.

[SVSooke]

Got the engine out of it's lair to be soda blasted.


Put the covers on to keep the soda and water out.Bit of a preview to.


After the blasting,not 100% done but I'll wash her down with thinners then paint it when it's warm and not humid.Might be a bit.

Did my rear master and my "new" ignition switch,Thanks Chuck! Remember the seized bolt?what a bear that POS is being.Welding a nut on didn't work.Possibly because I drilled it though.Engineer at work is going to fill it and redrill.May have to helicoil or Timecert(sp) to after.Grrrr.....

[Good Times]

Good work SV!

[psyguy]

it's a heavy bugger that engine, eh?

[SVSooke]

Not exactly light psy.Once the engine is done I think we are getting close to putting things back together.

[rustybronco]

Remember the seized bolt?what a bear that POS is being.Welding a nut on didn't work.Possibly because I drilled it though.Engineer at work is going to fill it and redrill.May have to helicoil or Timecert(sp) to after.Grrrr.....

Greg, what part has the broken bolt on it?

[SVSooke]

Greg, what part has the broken bolt on it?

The rear caliper,where it bolts on to the carrier.Seized like crazy.Only bad bolt on the whole bike.Grrrr.........

[chuck hahn]

Greg..get it hot as possible with a propane torch and throw in a pan of old motor oil over night. Then have the engineer guy use a left handed bolt tap and tap it down the center. Get a left handed thread bolt and screw it in. The left handed bolt will tighten and just keep turning left and the core will just screw right out..

[chuck hahn]

I have also removed broken exhaust bolts with left handed thread trick..works well for many applications.

[SVSooke]

Been off 5 days for my mother in laws 70th birthday.Out of town visitors you knowSee if he got something done today

In the mean time I got a bunch of stuff painted and polished up

[SVSooke]

Got to work and the bolt was out!Painted it up last night.Picks to come.

[SVSooke]

And here they are:


The apart pics.



And the done ones

[SVSooke]

Washed and blew off the engine today in preparation for painting.Now I have to wait for a sunny kind of warm day,none of those in forecast soon.Last big piece I need done before the reassembly starts.