The 2,298 Mile Wes Cooley

[rudeman]

Rich, can you post a picture of the tool you made or a link to the process, I would love to rebuild both of mine as I'm sure they have never been touched, I've heard 15W is the right fork oil to use for these bikes, what are you using?

I used 15W in my 1000EN and 1000ST and it works quite well.

[Vmass]

Rich, can you post a picture of the tool you made or a link to the process, I would love to rebuild both of mine as I'm sure they have never been touched, I've heard 15W is the right fork oil to use for these bikes, what are you using?

Sure will, I will also take a shot of the internals. The tool couldn't be simpler, a 24" threaded rod with two 1/2" bolts at each end. I will take a picture or two one night this week.

I didn't look into the fork oil, looks like Rudeman ha us covered.

[Vmass]

Below is a picture of all the components of the left fork, with the exception of the fork seal.

Also pictured is the "Fork Tool". The fork tool is used to hold the cylinder from spinning, as you remove the hex bolt from the bottom of the outer tube. Once the hex bolt is removed, you can remove the inner tube from the outer tube.

I found the " Fork Tool" mentioned in several threads.....here of course! The picture shows where I located the bolts and it worked well for me.

The outer leg has been stripped and ready for a little hand polish.



The tool is simply a 24" threaded rod with 4 1/2 nuts. I placed them a 1/2 up from one end and approximately 8" on the other end.

[Vmass]

I have one fork reassembled. Seal was replaced, as well as the 3 O-rings and drain screw. The hardest part was getting the new seal in far enough to allow the washer and snap ring to go back in.

I used the pvc pipe method. I may have been wasting some hits with the hammer, as the pvc is just a bit smaller than the ID of the lower tube. So, after a hit, you need to b sure the pvc is precisely over the seal, otherwise the fork lower will take the next hit.

I guess my biggest concern was forcing the seal in too far, resulting in squishing/damaging the new seal.

A change of weekend plans!!!!! I think I will get some garage time today!

[Kiwi Canuck]

Thanks for the photo's Rich, I get it now.

Looks pretty simple.

[Vmass]

Last weekend I put the rebuilt front forks and new front tire on. The fork project went well and easier than I expected.

I am doing my best to keep this bike as original as possible. Before I removed the old clear coat from the left leg, I carefully removed the Air suspension label. However, since the fork oil had been leaking for years, it worked its way behind the decal and took some of the color away. Too bad, I may or may not use it. If I don't use it, maybe I will be able to source one.

Yesterday I found a couple hours and thought I would rebuild the front calipers. I pulled them apart expecting to find some pitted piston cups. To my surprise, the calipers are in fantastic shape. The pads even look new.

The only component that showed wear was the piston boot. It had deteriorated from seepage.

I thought I had purchased a couple of front caliper rebuild kits a while ago. When I went to look, I didn't see them. After looking for the kits online, seems they don't exist for the 79's. I need to order the boots, O-rings etc. individually and hopefully install all the front brake components next weekend.

[steve murdoch]

I remember a couple years ago ordering from E-Bay what i thought were front caliper kits that turned out to be rears.
Apparently their mistake, my fault.
Are the E and S calipers the same? No doubt shipping would kill this deal.

http://www.ebay.co.uk/itm/Suzuki-GS-1000-E-front-brake-caliper-seal-repair-kit-set-1978-1979-1980-/151192458473?pt=UK_Motorcycle_Parts_13&hash=item2333c5d4e9

[Vmass]

I remember a couple years ago ordering from E-Bay what i thought were front caliper kits that turned out to be rears.
Apparently their mistake, my fault.
Are the E and S calipers the same? No doubt shipping would kill this deal.
http://www.ebay.co.uk/itm/Suzuki-GS-...item2333c5d4e9

The kit you linked to does not look like what I need. On this 79' I need the following for each caliper:

Two dust boots(one for the mounting arm and one for the piston)
One piston seal
Two O-rings for slider bolt
Bleeder and cap
$26.00 per caliper for the above parts through partfish (Steve?)

All of the above parts are available through Suzuki and need to be ordered individually, which is what I have done.

[Kiwi Canuck]

I am doing my best to keep this bike as original as possible. Before I removed the old clear coat from the left leg, I carefully removed the Air suspension label. However, since the fork oil had been leaking for years, it worked its way behind the decal and took some of the color away. Too bad, I may or may not use it. If I don't use it, maybe I will be able to source one.

Rich, those decals are available, I think it was the same vendor that sells the round vinyl engine decals from the UK.
They do the chain guard and the fork leg decal, I was talking to them via email but never did order, I'll take a look later to see if I can find the emails.
Reproduction Decals may also do them, as they do replacement VIN# stickers, IIRC.

What are you doing for brake hoses?

Nice to see your progress on 2298, looks like it's going to be another stunning Cooley restore by VMASS.

Cheers,

David

[Vmass]

Rich, those decals are available, I think it was the same vendor that sells the round vinyl engine decals from the UK.
They do the chain guard and the fork leg decal, I was talking to them via email but never did order, I'll take a look later to see if I can find the emails.
Reproduction Decals may also do them, as they do replacement VIN# stickers, IIRC.

What are you doing for brake hoses?

Nice to see your progress on 2298, looks like it's going to be another stunning Cooley restore by VMASS.

Cheers,

David

Thanks David!

For the brakes lines I used an Apex line for the rear and will also use an Apex for the upper front. The lower front lines (part # 59240-49400) are still available from Suzuki and I will use those.

I wish the rear Suzuki line was still available, as the Apex doesn't quite have the same look. The front upper line doesn't matter much as it is not all that visible.

[Kiwi Canuck]

Thanks David!

For the brakes lines I used an Apex line for the rear and will also use an Apex for the upper front. The lower front lines (part # 59240-49400) are still available from Suzuki and I will use those.

I wish the rear Suzuki line was still available, as the Apex doesn't quite have the same look. The front upper line doesn't matter much as it is not all that visible.

I used Apex for both front and back and the front top came with 45 degree offsets and was very tricky getting it to fit properly, I think it should be about 22.5 or 30 degree offset to match the factory spec.

Also the double banjo bolts from Apex were too short, I cleaned up the original one and reused it.

Agree on the rear hose, looks a little skinny, but couldn't find anything better so that's what I've stayed with.

Cheers.

[Vmass]

Rich, those decals are available, I think it was the same vendor that sells the round vinyl engine decals from the UK.
They do the chain guard and the fork leg decal, I was talking to them via email but never did order, I'll take a look later to see if I can find the emails.
Reproduction Decals may also do them, as they do replacement VIN# stickers, IIRC.


Cheers,

David

I found the decal supplier you mentioned on eBay. I will order a couple and hope I get the 1st one on correctly!

Link to decal supplier:

http://www.ebay.com/itm/SUZUKI-GS1000-GS1000E-GS1000G-FRONT-FORK-AIR-SUSPENSION-CAUTION-WARNING-LABEL/140959556181?_trksid=p2045573.c100033.m2042&_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20131017132637%26meid%3D8440fc347d8e4effbb0d6b59163cda55%26pid%3D100033%26prg%3D20131017132637%26rk%3D1%26rkt%3D4%26sd%3D140959556181

[Vmass]

I found the decal supplier you mentioned on eBay. I will order a couple and hope I get the 1st one on correctly!

Link to decal supplier:

http://www.ebay.com/itm/SUZUKI-GS100...3D140959556181

Not much progress as of late. I did receive the decal listed in the above auction. It came through slightly smaller than the original, everything else about it is dead on.

I sent the seller the dimensions of the original and he agreed to make some the correct size. However, he dropped the ball and did not follow through. After about five emails of him saying " ya, I can do that, send me the dimensions"....I gave up.

I hope to get this bike ready to go, shortly after the holidays.

[Vmass]

I rebuilt the front calipers today using all OEM parts. Calipers, pistons and slides were all exceptionally clean, a result of only a couple thousand miles. The original pads have virtually no wear, so those will remain.

I replaced the two lower brake lines with OEM lines and the upper line with a black APEX line.

I also rebuilt the front master cylinder. However, something doesn't feel quite right so I plan on pulling it apart again. It may be nothing but it seems like the plunger grabs/snaps a bit. Most likely due to being dry but I would like to make sure.

[Kiwi Canuck]

Rich, nice to see you making some progress on the bike, at least someone is working on their bike.

I've had 10 days off work and haven't done much bike work except help a fellow GSR member with his carbs, just spending time with the family doing holiday things and hanging out with my boys playing pool and darts and catching up.

I really thought I would get quite a bit of time in the garage but haven't had the urge for some reason.

Keep up the great job, I can live vicariously through you.

Happy New Year.

Cheers,

David