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1980 GS1000S Reluctant Rebuild

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    #166
    Stunning rebuild, Kiwi. Good luck with the fire up.
    Spoke with a seasoned UJM mechanic last night over a few barley pops, and mentioned the air cleaner bolt-up problem. His (smart-azz) comment: shim the motor 2° forward

    btw: those Pings look a bit neglected...
    '80 GS1000ST
    '92 ZX-11
    Past rides: '79 GS1000SN, '84 GPZ900R

    http://totalrider.com/

    Comment

      #167
      New Parts

      Finally got my last shipment of parts needed (ha ha) I know I will always need something else but it feels like I'm close to having everything I need.

      Ordered new rear brake pads from Suzuki, not sure why as I could have got aftermarket ones for 1/2 the price, maybe they are twice as good.

      Also got a few other misc. goodies needed, including a new gasket and 3 new acorn nuts for the oil filter.



      Look what I discovered when I went to install the filter cover, it didn't feel quite right when I tightened it up.



      Two very thin washers on the bottom stud, very strange, I'm not sure how it sealed with it like that. Just another example of fine workmanship from the PO.
      2018 Honda Africa Twin AS
      2013 DR 650 Grey, sold 1981 GS 650E Silver,
      1980 GS1000ST Blue & White, X2
      2012 DL650 Vstrom Foxy Orange, in storage
      1981 CT110 X2 "Postie Bikes" Gone to a New Home.
      2002 BMW 1150 GS Blue & White - Sold
      1975 BMW R90/6 Black - Sold 1984 GS1150EF Sold
      1982 BMW R100 Africa trip, Stolen - Recovered- Sold
      1977-1980 Suzuki GS550, GS1000E, GS1000S GSX750, GSX1100,s
      Hondas ST90, CR125 CB175 , CB350 CB750, NSU Quickly, Yamaha RD's 350/400,

      Comment

        #168
        Thanks

        Originally posted by Frank Z. View Post
        Stunning rebuild, Kiwi. Good luck with the fire up.
        Spoke with a seasoned UJM mechanic last night over a few barley pops, and mentioned the air cleaner bolt-up problem. His (smart-azz) comment: shim the motor 2° forward

        btw: those Pings look a bit neglected...
        Thanks for the kind comments Frank, and yes those fine golf clubs haven't seen much use this year, not sure why.
        2018 Honda Africa Twin AS
        2013 DR 650 Grey, sold 1981 GS 650E Silver,
        1980 GS1000ST Blue & White, X2
        2012 DL650 Vstrom Foxy Orange, in storage
        1981 CT110 X2 "Postie Bikes" Gone to a New Home.
        2002 BMW 1150 GS Blue & White - Sold
        1975 BMW R90/6 Black - Sold 1984 GS1150EF Sold
        1982 BMW R100 Africa trip, Stolen - Recovered- Sold
        1977-1980 Suzuki GS550, GS1000E, GS1000S GSX750, GSX1100,s
        Hondas ST90, CR125 CB175 , CB350 CB750, NSU Quickly, Yamaha RD's 350/400,

        Comment

          #169
          Originally posted by Frank Z. View Post
          Stunning rebuild, Kiwi. Good luck with the fire up.
          Spoke with a seasoned UJM mechanic last night over a few barley pops, and mentioned the air cleaner bolt-up problem. His (smart-azz) comment: shim the motor 2° forward

          btw: those Pings look a bit neglected...
          A thought just occurred coming from this post.Are you SURE the front motor mounts are the right way around? Just might make a bit if a difference,not sure it will but might be worth a look.

          Comment

            #170
            "As I’m trying to get everything ready to fire her up, any advice on pre-startup procedures before I push the button."

            fire extinguisher....and a video camera.
            Rob
            1983 1100ES, 98' ST1100, 02' DR-Z400E and a few other 'bits and pieces'
            Are you on the GSR Google Earth Map yet? http://www.thegsresources.com/_forum...d.php?t=170533

            Comment

              #171
              Originally posted by SVSooke View Post
              A thought just occurred coming from this post.Are you SURE the front motor mounts are the right way around? Just might make a bit if a difference,not sure it will but might be worth a look.
              Nice suggestion here, SV. Just checked, and whereas the right mount could be mistakingly installed backwards/rotated, it appears the left one can only go one way. Still wondering if carb-to-head boots have a right/wrong situation

              Originally posted by azr View Post
              "As I’m trying to get everything ready to fire her up, any advice on pre-startup procedures before I push the button."

              fire extinguisher....and a video camera.
              Priceless
              '80 GS1000ST
              '92 ZX-11
              Past rides: '79 GS1000SN, '84 GPZ900R

              http://totalrider.com/

              Comment

                #172
                Originally posted by Frank Z. View Post
                Nice suggestion here, SV. Just checked, and whereas the right mount could be mistakingly installed backwards/rotated, it appears the left one can only go one way. Still wondering if carb-to-head boots have a right/wrong situation



                Priceless
                So I needed to remove the carbs because I forgot to install the starter motor bolts and I didn't feel like messing around with trying to install them with limited space, so out they came.
                I have measured the cylinder intake boots 6 ways to Sunday and they are in fact symmetrical no different either way up.
                SV good thought on the engine mounts, already thought of that but as the rear and lower mounts are fixed it's actually not possible to get it in wrong.
                2018 Honda Africa Twin AS
                2013 DR 650 Grey, sold 1981 GS 650E Silver,
                1980 GS1000ST Blue & White, X2
                2012 DL650 Vstrom Foxy Orange, in storage
                1981 CT110 X2 "Postie Bikes" Gone to a New Home.
                2002 BMW 1150 GS Blue & White - Sold
                1975 BMW R90/6 Black - Sold 1984 GS1150EF Sold
                1982 BMW R100 Africa trip, Stolen - Recovered- Sold
                1977-1980 Suzuki GS550, GS1000E, GS1000S GSX750, GSX1100,s
                Hondas ST90, CR125 CB175 , CB350 CB750, NSU Quickly, Yamaha RD's 350/400,

                Comment

                  #173
                  My helpers

                  Got some help in the garage today, Alexander helping with polishing the exhaust pipes.

                  2018 Honda Africa Twin AS
                  2013 DR 650 Grey, sold 1981 GS 650E Silver,
                  1980 GS1000ST Blue & White, X2
                  2012 DL650 Vstrom Foxy Orange, in storage
                  1981 CT110 X2 "Postie Bikes" Gone to a New Home.
                  2002 BMW 1150 GS Blue & White - Sold
                  1975 BMW R90/6 Black - Sold 1984 GS1150EF Sold
                  1982 BMW R100 Africa trip, Stolen - Recovered- Sold
                  1977-1980 Suzuki GS550, GS1000E, GS1000S GSX750, GSX1100,s
                  Hondas ST90, CR125 CB175 , CB350 CB750, NSU Quickly, Yamaha RD's 350/400,

                  Comment

                    #174
                    More help

                    John has been helping with a bit of wrenching as well.

                    Here he is helping with the exhaust install.



                    Now back to the real chores.

                    2018 Honda Africa Twin AS
                    2013 DR 650 Grey, sold 1981 GS 650E Silver,
                    1980 GS1000ST Blue & White, X2
                    2012 DL650 Vstrom Foxy Orange, in storage
                    1981 CT110 X2 "Postie Bikes" Gone to a New Home.
                    2002 BMW 1150 GS Blue & White - Sold
                    1975 BMW R90/6 Black - Sold 1984 GS1150EF Sold
                    1982 BMW R100 Africa trip, Stolen - Recovered- Sold
                    1977-1980 Suzuki GS550, GS1000E, GS1000S GSX750, GSX1100,s
                    Hondas ST90, CR125 CB175 , CB350 CB750, NSU Quickly, Yamaha RD's 350/400,

                    Comment

                      #175
                      Nice to see your not in this project alone. I hope you give them encouragement to learn wreching techniques in nicer language than my step dad. In my day I was lucky to have a lawn mower with wheels, let alone a motor.
                      sigpic
                      83 GS1100g
                      2006 Triumph Sprint ST 1050

                      Ohhhh!........Torque sweet Temptress.........always whispering.... a murmuring Siren

                      Comment

                        #176
                        WHat happens when you clamp the carbs to the airbox first then push up into the intake?
                        Cowboy Up or Quit. - Run Free Lou and Rest in Peace

                        1981 GS550T - My First
                        1981 GS550L - My Eldest Daughter's - Now Sold
                        2007 GSF1250SA Bandit - My touring bike

                        Sit tall in the saddle Hold your head up high
                        Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
                        and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

                        Comment

                          #177
                          New pictures

                          Here are the pictures that show the misalignment of the carbs to the Air Box, the only conclusion I have come to is the intake boots have been replaced and are not the same as the original ones.
                          Cowboy, does not make a difference which side I put in first, the box is low by about 1/2" and the bolt holes will not line up.
                          When I lift the airbox to align the bolt holes the rear boots slip off, as the new band clamps are a little too big.
                          Not a big deal as long as the air filter box fits and I can bolt that down so it should hold everything together.

                          This picture is with the carbs in the neutral position, just where they sit.



                          Here the side view with the airbox in it's "correct" position.

                          2018 Honda Africa Twin AS
                          2013 DR 650 Grey, sold 1981 GS 650E Silver,
                          1980 GS1000ST Blue & White, X2
                          2012 DL650 Vstrom Foxy Orange, in storage
                          1981 CT110 X2 "Postie Bikes" Gone to a New Home.
                          2002 BMW 1150 GS Blue & White - Sold
                          1975 BMW R90/6 Black - Sold 1984 GS1150EF Sold
                          1982 BMW R100 Africa trip, Stolen - Recovered- Sold
                          1977-1980 Suzuki GS550, GS1000E, GS1000S GSX750, GSX1100,s
                          Hondas ST90, CR125 CB175 , CB350 CB750, NSU Quickly, Yamaha RD's 350/400,

                          Comment

                            #178
                            David, I'm pretty sure everything will be just fine once you can clamp the airbox boots to the carbs before you pull the airbox up to bolt it to the frame. Lots of bikes I've worked on are the exact same distance from the frame bolts. The carbs just bend up a bit without the boots coming off.
                            Rob
                            1983 1100ES, 98' ST1100, 02' DR-Z400E and a few other 'bits and pieces'
                            Are you on the GSR Google Earth Map yet? http://www.thegsresources.com/_forum...d.php?t=170533

                            Comment

                              #179
                              No Go Tonight

                              Well I had my Video Camera and Fire Extinguisher ready but could not get the starter button to work, had lights and dash was all lit up, when I was checking the fuse panel to see what voltages I was getting I noticed a hot fuse so I quickly disconnected the battery.
                              I checked all the fuses and the first two were 20 and 25 Amps no wonder I had a few melted wires when I got the bike.
                              It looks like something is shorting somewhere, so I'll leave it till tomorrow to look at it.

                              I'm knackered as I must have taken 2-3 hours just to finish getting the exhausts on tonight.
                              I put them on and took them off about 3 times until I realised that the header pipes for 1 and 4 are handed, who knew? and I had them on the wrong side and struggled for an hour trying to get the left pipe to fit on the right side. Once I got that sorted I still needed to get the bolts aligned at the back and they did not line up without a big of leverage.

                              Seems strange that they didn't just drop straight on as they supposedly came off this bike.
                              Would have been nice to hear the bike start after all that work, I did jump the starter solenoid wire to the battery and turned it over so that all works.

                              Tomorrow is a holiday here so hopefully I'll get a bit of time to look at the electrical issue then.
                              2018 Honda Africa Twin AS
                              2013 DR 650 Grey, sold 1981 GS 650E Silver,
                              1980 GS1000ST Blue & White, X2
                              2012 DL650 Vstrom Foxy Orange, in storage
                              1981 CT110 X2 "Postie Bikes" Gone to a New Home.
                              2002 BMW 1150 GS Blue & White - Sold
                              1975 BMW R90/6 Black - Sold 1984 GS1150EF Sold
                              1982 BMW R100 Africa trip, Stolen - Recovered- Sold
                              1977-1980 Suzuki GS550, GS1000E, GS1000S GSX750, GSX1100,s
                              Hondas ST90, CR125 CB175 , CB350 CB750, NSU Quickly, Yamaha RD's 350/400,

                              Comment

                                #180
                                Originally posted by azr View Post
                                David, I'm pretty sure everything will be just fine once you can clamp the airbox boots to the carbs before you pull the airbox up to bolt it to the frame. Lots of bikes I've worked on are the exact same distance from the frame bolts. The carbs just bend up a bit without the boots coming off.
                                I fully agree with AZR
                                Everything is normal, you just need to lift the airbox with the carbs attached and it will work fine.
                                Don't forget that the carbs are "hanging" without the airbox attached.
                                sigpicJohn Kat
                                My bikes: CB 77, GS 1000 ST Cafe Racer with GSXR 1052 engine, GS 1000 ST, XR 41 Replica with GS 1085 engine,
                                GS 1100 SZ Katana with GS 1135 EFF engine, KTM Superduke 1290 R 2020

                                Comment

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