My 1980 Suzuki GS1000G

[azr]

azr, for the pan, I would just take a wire wheel to it, prime it with red oxide primer and paint.

Going to be watching this build and wishing you clear sailing towards its completion.
BYW, 1000G's are sweet!

Daniel

Thanks for the tip Daniel, that looks like just the stuff. The stock edging is still intact so I'll just warm it up and glue it back on. Never put a seat cover on but can't be too hard. Looks like the one thing to remember is keep the cover warm and don't use glue.

[rustybronco]

The pans in fairly good shape, shouldn't take much at all to get it looking like new. Not sure what is the best filler, if any, on the metal to smooth things out.

I wouldn't worry to much about filler, primer will take care of most of the pitting on the bottom side of the seat. the top side (foam side) wont matter if it's a bit pitted as you will be gluing the foam over the pitting. what I would suggest is you sand (media) blast it to remove all the rust.

[azr]

Well I'm slowly making progress. The seats all done with the exception of grommets for the seat bar which I'll have to try and find somewhere because I'm too cheap to pay the $20 (and I don't think they are worth that much). The top end has been soda blasted, honed and had the valves cleaned up.



This was my first time for doing honing (did it with an old school bike mechanic from Britain, cool guy). Did the valve lapping on my own, was pretty easy.



My last big batch of parts from Boulevard showed up so I can start putting the pistons and head back together.



I'll read around here for tips on re-installment but if anyone has any feel free to throw them in. I put new base and head gaskets in my old 79 850 but have never done rings or valve seals. I'll get a hand with the pistons going back in, I did it on my own last time and it would have been a lot easier with an extra pair of hands to hold the rings (I don't have a ring compressor). And I solved the issue of faded RPM gauge, bought a better one from the salvage yard. It was a lot of work to open up both clusters and put it back together, I wouldn't want to do that very often, but it's nice to know it can be done.



I've got the POR-15 chassis black to paint the frame and all the tid bits with. Really looking forward to seeing the results from that if the weather ever warms up around here to let me get it done. The o-rings are on their way from Mr. Barr so I can do that and the cam tensioner, guess I've got a few things to do while it's still cold out.

[jhillier449]

Great job.

I'm going to do the motor when it gets a bit warmer on my 1000G, can you post pics of the gasket placements with all the bits when you put it back together?

I'd like to see where all the o rings and washers etc. go on the bottom of the jugs and on the cylinder head.

cheers

John

[azr]

Will do, though it's pretty self explanatory when you get down to it.

[azr]

Few more things done.



Took longer than I had expected but the new seals are in and the head is all buttoned back up. Ready for paint now.



Had everything here for the petcock so did that as well. Decided not to paint it as it sits in front of the carbs which won't be painted either so I just cleaned it up and put the new parts in.



Sure moves real nice now. I'll have to throw it on a tank to test it.

[azr]

Seats all done. Looks fantastic thanks to a few donations of cover and grab bar. I'll have to see how the grab bar works with the Samsonite luggage once she's all put together.





If you look closely you'll notice I resolved the grommet issue, and just my kind of price, $2.

[7981GS]

She is coming along nicely. She will be a keeper no doubt.

Daniel

[Charlie G]

I'll remember that grommet trick. Saddlemens cover, I'd say...looks good.

cg

[rustybronco]

Nice looking seat!

[SVSooke]

So this is what you've been up to.Looking good remember seeing it part way through the disassembly.Popped the $ for those washers

[bbjumper]

Lookin good

That seat looks great, where did you get the cover and yes, the cylinder goes back on allot easier with an extra set of hands.......

[Wallowgreen]

Looking really good Rob, this the machine you're hoping to use in August?

[azr]

The seat cover was a donation from '850 combat', a used Saddleman cover and that shinny handle was another generous donation from 'rustybronco'. Fit on easily and I'm happy with the look. I see there's currently a discussion going on about Saddleman VS Pitreplica. Yes, this is the bike I'm hoping to have running for this season. If I get my butt in gear it 'should' be ready I've got a full set of Samsonite bags to go on her as well. I'm hoping she will be the full meal deal bike. Good for ridding locally and for touring.

[azr]

Aaaaarrrrrrrrrrrr.........

Finally spent some time with the old 1000G again, 10 minutes into working on her again and one of the cam cap bolts breaks off in the head.....ahhhhhhhhh.... No warning at all. It was the 2nd to last bolt and hadn't even got close to torque pressure, didn't even get a hint of it getting tight, must have been a crack or something in the bolt I figure. Tried drilling, started a real nice straight hole, thinking "this is actually going to work" and the bit broke off in the hole....AARRRRRRRRR. Tomorrow I'll find the hardest bit I can find and try one last time, but I can't imagine I'm going to be able to drill through a metal bit. Some days it's just better to go back to bed.



Any suggestions or condolences are appreciated.