Progress!!! 1978 GS1000E Restoration/Performance Rebuild

[azr]

hopefully those are good enough

[philosopheriam]

hopefully those are good enough

THANK YOU! I totally forgot where/how the brackets mount - duh!

[philosopheriam]

Got a bunch of stuff done today, so, here is a little video teaser (click)

Enjoy!



Wire harness installed in bike
All battery cables, starter, and ground cables fabricated and installed
Rear brake switch and spring installed
Rear brake/tail light installed

[JonnyC]

I was going to say "really clean! Awesome work!", and then I saw how dirty that starter is Kidding!

[80GS850GBob]

Just a refresher....1st cruise night of the season is May 7th at A&W in N Aurora {starts 6pm} ...then Lake St in front of Ace afterwards{9pm} till ?am. Cycle or not.....weather playing nice, of course too. {it's Illinois - it could snow like two Saturdays ago}

[philosopheriam]

Just a refresher....1st cruise night of the season is May 7th at A&W in N Aurora {starts 6pm} ...then Lake St in front of Ace afterwards{9pm} till ?am. Cycle or not.....weather playing nice, of course too. {it's Illinois - it could snow like two Saturdays ago}

I doubt that the gs will be done by then, however, I may show up on my fz6!

[80GS850GBob]

I doubt that the gs will be done by then, however, I may show up on my fz6!

Well, I was brought up with "it's always nice to be asked".....I'm sure george{cb750 brat}, steve{kawi concours} and wally{hd dresser or his vw wagon} will probably be there...me, life has kept me away from working on the cycle for a while...ugh. Need to start going thru mine soon!

[philosopheriam]

Help...

Can someone snap a quick photo of the proper positioning of the clutch release arm - I can't remember how much it was clocked on the clutch shaft. Thanks!

[ShadowFocus603]

Where did you buy your wire? I can find the weatherpack connectors and solid color wire but I can't seem to find any wire with the white/black tracer on it. Your harness inspired to start looking at mine lol. I am planning on finding a second harness to rebuild from so my bike doesn't spend any time down.

[philosopheriam]

Where did you buy your wire? I can find the weatherpack connectors and solid color wire but I can't seem to find any wire with the white/black tracer on it. Your harness inspired to start looking at mine lol. I am planning on finding a second harness to rebuild from so my bike doesn't spend any time down.

For the wire, eBay is your friend - do a search for "18 txl wire"

For connectors, try this guy www.cycleterminal.com

[ShadowFocus603]

Quick question. What controls did you get? I might have missed it sorry. I like how clean they are and not bulky.

[philosopheriam]

Quick question. What controls did you get? I might have missed it sorry. I like how clean they are and not bulky.

They are made by K&S technologies - check out this link:

http://www.kandstech.com/index.php?page=switchescontrols

I have the 12-0041B and the 12-0203

[philosopheriam]

Progress over the past 2 to 3 weeks...

There haven't been any weekly updates because most of what I have been doing is fiddly farting around with cables - my buddy has all of the parts to fabricate custom cables, but because I am unable to bring the bike to his shop to fit each cable, there is some guesswork involved. Four trips back and forth from the suburbs to Chicago :-/

Long story short, the throttle cables are a push/pull setup originally intended for a Honda - each cable had to be shortened, and it took us a few tries to get the length of the pull housing/cable correct. Because of the lower handlebars, I had to route the cables under the triple clamp.

The clutch cable has the upper portion (90 degree bend) from an EX500 cable and the lower portion is completely fabricated. I reused the spring, bellows, and rubber boot from the original clutch cable. And adjuster was installed at the same location as the original.

[philosopheriam]

Progress over the past 2 to 3 weeks (continued:

When I went to clean and reassemble my old ignition switch, removing 38yrs of grime revealed a crack in the switch body. This, combined with the fact that the lock mechanism itself was in sorry shape convinced me to track a down a decent used one off of eBay. Success! I found one that was in excellent shape that I was able to move most of the wafers around to fit my original key - I only had to file 2 wafers a tiny bit to make it work smoothly. I soda blasted the body of the switch to get it ready for paint.


I filed/sanded some gouges out of my levers and polished them



I built a small angled bracket to mount the crankcase breather - This bracket mounts to an existing frame bracket (for the original air cleaner)

[philosopheriam]

Progress over the past 2 to 3 weeks (continued):

Last week, I installed the remainder of the ignition system components (minus the ignition wires) and statically timed the engine to around 35 degrees BTDC. I eliminated the Dyna's molex connector near the timing plate and used a 4-pin Amphenol ATM that is weatherproof.