New to me GS1000G

[JTGS850GL]

Received the parts needed to install the new stator and the now polished clutch over. What's the best way to install the covers? Should I use any type of gasket sealer or install with the gasket alone. The clutch cover was covered with RTV. I know it's not a good idea to use it so I removed all the old RTV and now asking for opinions on what to use.

I'll post pics once everything is installed.

Next step is to install the carbs and airbox. After that I need to install the new R/R and get her running!!!

[Dogma]

Gaskets go on dry. I think the only thing on a GS that gets sealant is the case halves. Non-hardening gasket dressing or a thin smear of grease can be used on the cam cover to try to get more than one use out of that gasket.

[Flyboy]

Gaskets go on dry. I think the only thing on a GS that gets sealant is the case halves. Non-hardening gasket dressing or a thin smear of grease can be used on the cam cover to try to get more than one use out of that gasket.

+1
Gaskets go on dry, I use a very thin film of light all purpose grease, that is all.
makes cleaning the gasket surfaces next time, a breeze, and as Dogma says, if you are careful, you can save the gasket and use it again.

RTV is real shade tree mechanics, I, want to throw a wobbly when I see a motor put together with tubes of RTV,

[azr]

Dry it is for sure. I do carry a small tube of "the right stuff" by Permatex on all my bike trips now though. I really think a tube of this, or any other tried and true high heat gasket maker, should be in everyone's took kit.

[JTGS850GL]

Dry it is. Thanks for the input guys.

Should be ready to install the carbs and airbox over the next couple days. The exhaust is another issue.

The bike came with the stock exhaust but the chrome is getting very thin in some places, it missing some of the clamps and the baffles are completely rusted out. I can hear the baffle remnants move around when I tilt the pipes back and fourth. Considering picking up a pair of V&H 4into1's but still wondering what to do with the stock exhaust? Are these pipes worth anything?

[azr]

Your pipes sound like they are scrap metal. You can weld on some aftermarket mufflers though. I did that with an 850 once. Welded on a set of Dunstalls. Looks great but was a bit loud, although I never packed it with proper baffle packing only steel wool.

[JTGS850GL]

OK, got a chance to do some more work over the last couple days.

The good:
Replaced front wheel bearings.

Assembled forks with new seals, wheels and rebuilt front brakes. Still waiting on some master cylinder parts to complete front brake assembly.

Installed new stator.

Installed and wired in new SH775 R&R.

Polished and installed stator, secondary drive and clutch covers.

Installed carbs and airbox. Still waiting on gasket for breather cover.

Assembled exhaust components and installed exhaust gaskets in head. Still need to mount exhaust.

The bad (so far):
Clutch seems to be dragging even after disassembly, repack and reassembly. Need to inspect all plates for warpage and thickness. Will see what happens after I get her started.

Choke cable broken. New cable ordered.

Gas tank is rusty inside. Will clean with Rust Rescue. I'll decide on whether to use POR15 after that.

Exhaust mufflers rotted out but did find all needed clamps.

Fuel gauge is not working correctly. Need to check wiring and sender before I condemn the gauge.

Pictures to follow….

[Big T]

If your tank is rusty, your fuel gauge sender is also rusty

[JTGS850GL]

Here's where she sits as of now:

Front end assembled but still waiting on a couple brake components before I can add fluid and bleed them. Still waiting on the new gauge back:


Pipes installed and derusted. Note on valve cover is to remind me the engine has no oil. Still looking for rectangular rear tail lights to match the front:




Carbs and air box mounted. Side covers polished up. Still waiting on emblems:




Replacement fuse panel installed and new R/R installed and wired in. Still have some clean up on mounting panel but that's for another time:


SH775 R/R mounted in the stock with just a minor amount of elongation of the mounting holes:


Replacement rear view mirrors came in as well:


Reconditioning the crash guards. One done and one to go:


Choke cable installed and instrument cluster getting buttoned up:


Still waiting on a number of parts but most are cosmetic. A few are critical though. I'll need them before I can start her up and begin the carb sync and tune process. Going to have to do some minor rust removal of the fuel tank as well.

That it for now... at least until some more parts arrive.

[JTGS850GL]

A little more progress:

New polished hex bolts and case guards ready for installation:




Began the process of stripping the tank for paint:

Here's where I am as of today. I coated the tank with oil to prevent flash rust:






Pretty surprised at how few dents and rust on the tank. Rattle can paint job came off pretty quickly with Aircraft brand stripper. Looked like it's been reworked before since none of the original paint was present.

The next step will be to de-rust the interior of the tank, fix any small dents and prime it for paint.

Still waiting on a breather gasket before I can try to start the engine after the carb rebuild.

Still concerned with the clutch not fully releasing when the engine is not running. Is it normal to not be able to crank the engine when in gear (clutch pulled in) without having the bike pull you down the road?

[JTGS850GL]

More parts arrived today so it was time to get on with it.

All the parts I needed to get the front brakes working arrived so I was able to fill and bleed the brakes. Still just a tad soft so I'll be tie wrapping the brake lever pulled in over night and see if that helps. Right now it feels much like my 850 so it's probably OK. Did pick up a little bling bling for the gauges:


New emblems did come in as well. The were indeed the later model black and gold emblems but I like them:




Started to prep the side covers for primer. Everything sanded down. The original clear coat was so bad that it just flaked off in most places. The covers had at least 3 different paint jobs so sanding them down took a little time:




New to me foot pegs arrived as well. Here's where we are today:

[eil]

Looking great!

[JTGS850GL]

Thank you!

[ged]

Looks like she is coming along very nice, well done.

Just for some info for me is the black wire from your RR going to an earth or is it to the negative on the battery. Regards

[JTGS850GL]

The black wire is going directly to the negative terminal of the battery.
The red wire is connected through the fuse block just like the original R/R.
The three yellow wires go straight to the three stator wires. No loop through the headlight bucket.