GS1000. On my own this time

[Flyboy]

1000s use all the verynsame intake manifolds..put them on wherever you want to start. I usually do the center 2 first and work outward.

Arrrhhhemmm, Jennifer's are marked L & R

[chuck hahn]

Yeah ive seen that before too..but never payed any attention to that. Some bikes do have those offset curved ones.

[Flyboy]

Ok, gotchya, probably the later ones, oh yes, you have the low performance heads for economy on yours, not like the G with the high performance head....

Hat - Coat - Door ----------------------------------------------->>>>

[RobertGS]

Thanks that helps. Gas tank day tomorrow, Monday. I'll post pictures of the soldering and tank liner efforts. Hoping shims arrive from Z1 tomorrow too.

[RobertGS]

Be kind, here are a couple of shots of my soldering of the two small holes in my tank. It seemed to hold just fine through various washings and cleanings of the por-liner I put in afterwards. The paint was already seriously killed and I'm redoing that soon so not concerned.

Here's the biggest hole


And one of the solder efforts..


I used acid flux and lead-solder. Washed the tank out multiple times with warm dish soapy water, followed by flushing with the hose, then applied the first stage of the por-liner kit which involves lots more washing and draining. Left the tank about half full of water when I did the soldering.

For drying the tank prior to putting in the actual liner I rigged my shop vac to suck air from under a blanket with a small space heater blowing in there. Makes for a pretty powerful blow dryer.


Other than that, carbs are back on the bike. I bought carb sync gauges and once I finish installing the new valve shims and close up the top end I'll get her started up again and see how it goes.

[RobertGS]

quick question about installing exhaust. The 4 silver exhaust gaskets. To be honest I don't remember how these install. I assume they just tuck in before you push the exhaust ports into the engine. They don't seem to fit snug inside the exhaust ports...a bit of wiggle room so they fall out easily.

So am I right that you just have to tuck them in (while at the same time managing those split gaskets on the inside two pipes... a bit of challenge.

Tips appreciated, but mostly just want to ensure I'm on the right track with these 4 silver circular gaskets.

[chuck hahn]

Yes they just set in the head. I have taken scotch tape and used small strips in strategic spots to hold the ones that want to fall out on the ends of the pipe instead. The tape burns right off soon as you start the bike. Use just enough to hold the gasket there so you can line it up and slide then pipes in the head.

[chuck hahn]

Good enough on the soldering..if it doesnt leak its a good deal. since its on the bottom I wouldnt even worry about smoothing it off. Tank liner is in so just clean it up and repaint.

[RobertGS]

Thanks Chuck,
Hoping to fire it up today and balance the carbs. Should be interesting to see how all this work turns out. Crossed fingers.

[Gregory]

Sorry about the slow pace. I get windows of time to work on the bike and finally have some updates.
Carbs are now dipped, new o-rings and back together and bench synced. Will be picking up carb sync gauges soon.

Cleaned up the intake boots and have new o-rings. Waiting to sort out new fasteners for those.

I remember seeing various posts about installing these in the correct orientation and that they are marked left and right... I don't see any markings on these and they appear pretty similar... Do the boots for a 791000N have markings I"m not seeing?



Clutch is back together with plates and springs in spec, ridges filed and nut torqued properly

Thanks to tkent02 I have a new tach unit in hand to replace the one with busted tach needle.

Gas tank is next. I'll be scraping off epoxy covering a puncture and using flame to solder it with old lead solder (I know many opinions on this and this is what I'm going with). Then a por 15 kit to line it.
Just for fun here's my home-made aux gas tank. 14 bucks in fittings and the jb-weld and bottle I already had.


I wish I had more time to keep it going more quickly. Takes me a while... I must have pulled the choke plunger rod out 10 times before I had those lifters in right, and that's just one piece. Tried getting an old o-ring off a jet for 10 minutes before figuring out an easy way (pinch them on either side and slide a plastic pick in to get them off).

I am intrigued by the auxiliary tank. Are you mounting it somewhere on the bike? and will it be always installed to the system?

[Big T]

Robert

The exhaust gaskets should fit pretty snugly against the head

You should check to confirm whether the old gaskets are still in there before installing the new ones. Use a pick or small screwdriver and confirm that the circular face around the exhaust port is visible

[chuck hahn]

Sometimes they do and sometimes they dont. I just put new ones on the 1000C and two stayed put and two wouldnt. its a crap shoot far as I can tell I. thats why i taped the two to the end of the pipe...3 tries and that was that.

[RobertGS]

Well something is up, because the pipes are just not going in there fully. So you may be right though I did shine a flashlight up in there previously and thought it was clear of old gaskets...maybe all covered up in soot?

So after an hour of wrestling guess I'm pulling them out again.

Will report.

To previous question re auxiliary gas tank... just going to use it while I sync the carbs.

[RobertGS]

So there are definitely no old gaskets in there and it looks to me like no gasket would fit. Is it possible the 79GS1000N takes no gasket? The exhaust is stock as far as I can tell.

What gives.

[chuck hahn]

They take gaskets. Got an old one to compare the OD measurements to?? Maybe take one and see just how close they are. If really close you may have to tap them into the head first and seat them against the head. Piece of PVC will work as a tool. Dont crush them..just get them in there???

http://www.partsoutlaw.com/oemparts/a/suz/50d402a8f8700230d8b4e858/muffler