New to me GS1000G

[JTGS850GL]

Mine is the rectangular one but much thanks for the offer. I've seen complete reservoir kits or $33 and internal rebuild kits for another $22. I'm still looking at my options but $55 for a complete rebuild looks good right now.

Anyone want to trade a rat's nets of bent oil cooler and lines for the stock sender and housing?

[JTGS850GL]

OK, the carbs are assembled and ready to be bolted on. That's assuming I can get a handle on that broken screw on the intake. Would like a sanity check to make sure everything looks correct. Especially the throttle and choke linkages:

[azr]

Carbs look they're done right. Did you do a bench synch? One tip, before you put the carbs into the head boots, connect both of the cables, don't tighten them down just get them in the tiny hole and the cable in it's channel. It's a bugger to do after the carbs are in the intake boots.

[Dogma]

Linkages are correct.

[JTGS850GL]

I did "bench sync" them as best as I thought how to. I used the throttle adjustment knob and a smooth paper clip to get the #3 carb set so the paper clip would just slide through with a slight resistance. I then adjusted the other carbs so the clip would slide through at about the same resistance. I thought of using a thin feeler gauge instead of the paper clip but decided otherwise since that would have required me to go out into the very cold garage.

Any suggestions on how to get that nasty broken screw out? I can just barely get a drill in there to drill it out if I have to.

Just waiting on the weather to break. It's getting down right nasty here in Atlanta. Not riding weather for sure. May not look like much to you northern folks, but it's all ice since it's been nothing but freezing rain and sleet. No snow yet but they're calling for 6 to 10 inches by tomorrow morning. Trees are already snapping from the wind and weight of the ice.

[Dogma]

Use left-handed drill bits. If you're lucky the drill will bite and back out the remainder of the screw.

It looks like there may be some screw left sticking out of the hole. You might try slotting it with a Dremel and back it out with a screwdriver. Even if you have to slot the aluminum a bit. If you have a welder you might try welding a nut to it. The heat helps loosen it in the aluminum too. Of course, you have to be careful not to melt the aluminum...

[hjfisk]

I did "bench sync" them as best as I thought how to. I used the throttle adjustment knob and a smooth paper clip to get the #3 carb set so the paper clip would just slide through with a slight resistance. I then adjusted the other carbs so the clip would slide through at about the same resistance. I thought of using a thin feeler gauge instead of the paper clip but decided otherwise since that would have required me to go out into the very cold garage.

Any suggestions on how to get that nasty broken screw out? I can just barely get a drill in there to drill it out if I have to.

Just waiting on the weather to break. It's getting down right nasty here in Atlanta. Not riding weather for sure. May not look like much to you northern folks, but it's all ice since it's been nothing but freezing rain and sleet. No snow yet but they're calling for 6 to 10 inches by tomorrow morning. Trees are already snapping from the wind and weight of the ice.

Looks like a typical week day storm to us.

[Big T]

Use left-handed drill bits. If you're lucky the drill will bite and back out the remainder of the screw.

It looks like there may be some screw left sticking out of the hole. You might try slotting it with a Dremel and back it out with a screwdriver. Even if you have to slot the aluminum a bit. If you have a welder you might try welding a nut to it. The heat helps loosen it in the aluminum too. Of course, you have to be careful not to melt the aluminum...

alternate heat and penetrating oil for a few days, then drill it

G exhaust is different from the E, a bit shorter

[JTGS850GL]

alternate heat and penetrating oil for a few days, then drill it

G exhaust is different from the E, a bit shorter

Will do. Wish me luck!

Things done so far:

Removed and rebuilt carbs
Removed the Vetter fairing
Replaced battery
Repaired the reversed clutch safety switch
Changed oil and filter
Replaced neutral indicator light bulb
Check compression (125 to 130 cold without carbs installed)


Items on the list that still need to arrive for the initial phase of the project:

New intake boots and O-rings
Front master rebuild kit
Front master reservoir kit
Front caliper pistons and seals
Complete headlight and turn signal assembly with mounting brackets
Front brake light switch assembly

Things I still need to get or do:

Adjust valve clearances
Order Saddleman’s seat cover
Order front fork springs and seals
Install all of the above ^
Clean tank and R&R petcock
Replace right side foot peg

This will not be a frame off restoration as of now. The goal is to get her running and rideable. Once that’s done I’ll see where this takes me. Phase 2 will be more cosmetic like repainting the tank, rear end piece and the side covers. Polishing the engine covers. Also expecting to be able to verify things that can only be checked with the engine running like the stator/RR output voltage, clutch and transmission. Usually these projects take a life of their own.

I’ll post some pics of the progress in a few.

[JTGS850GL]

Some goodies came in today:

I found a set of OEM caliper rebuild kits:





Kits cost just under $16 each as NOS.

Airbox will be much happier as well:



Still need to replace the missing weather stripping though.

Here's where I am today overall:




Needed to bypass the oil cooler until I pick up the stock housing:


Master cylinder bake parts are coming together:

[Gregory]

.


New DIY sonic cleaner to replace my trusty but now dead Branson:

cool... I would love to see the build specs for this.

[JTGS850GL]

Here's a thread on the construction of the sonic cleaner:

http://www.thegsresources.com/_forum/showthread.php?t=216754

So far it's worked out great.

[Gregory]

Here's a thread on the construction of the sonic cleaner:

http://www.thegsresources.com/_forum/showthread.php?t=216754

So far it's worked out great.

Thanks you i will read it now

[eil]

Your K&N filter came with two packs of oil... mine came with one. I applied the whole thing to the filter but didn't read the instructions closely enough until afterward... I was only supposed to put 1/2 of the pillow on the filter. So just a friendly reminder to double-check the instructions.

[JTGS850GL]

My instructions say to use one of the oil packs but it is strange that it came with two. Maybe mine are smaller then the one you received. Filter is now oiled and installed in the air box. Waiting on the boots to arrive from Z1.