Progress!!! 1978 GS1000E Restoration/Performance Rebuild

[philosopheriam]

Agreed. I painted my Telefix with Caliper paint and baked it. Holding up well.

Nice work, Anthony. Now hurry up and finish this beast we're getting impatient...

This weekend:
Rebuild and paint front master cylinder
Install chain
Bleed rear brakes
Install bodywork

I'm working on it, Rudy!

[philosopheriam]

I need a favor from someone:

Can anyone snap a photo of the rear disc as it sits inside the rear caliper - i.e. is it perfectly centered or is it offset to one side or the other just a smidge. Thanks!

[alke46]

Mine appears to be just a smidge offset towards the outside of the caliper. Sorry, can't do pics just now.

[philosopheriam]

Mine appears to be just a smidge offset towards the outside of the caliper. Sorry, can't do pics just now.

Yep, mine is the same, offset to the outside of the caliper a smidge.

[80GS850GBob]

How's this? Yell if you want a different angle...
Just got back late last night from the Smokey Mountains....I have a new direction I want to go!{Snake/Dragon's tail}...too many HDs there{99.9%)...and not enough old asian representation.last A&W work and cycle 001.JPG

[philosopheriam]

How's this? Yell if you want a different angle...
Just got back late last night from the Smokey Mountains....I have a new direction I want to go!{Snake/Dragon's tail}...too many HDs there{99.9%)...and not enough old asian representation.[ATTACH=CONFIG]47002[/ATTACH]

Bob - you da man! Mine looks identical to yours. I just wanted to make sure my rear wheel bearings were seated correctly. Thanks bunches.

[80GS850GBob]

No problem...here to help when I can. {reminds me I still need new rear brake pads}
Btw - not to hijack the thread and just to clarify, "the snake" and "the dragons tail" are two Tennessee area roads {among many others} that are pure motorcycle road porn....tons of turns and switchbacks in only 50 or so miles each...

[philosopheriam]

Folks,

I apologize for the lack of updates in the past few weeks - the bike should have been completely finished by now. I was making tons of progress until I ran into a significant issue with the modified rear swingarm. Although this problem is *not* insurmountable, it is without a doubt profoundly irritating. Take a look at the photos and you'll see what I mean:

When I pinned the chain last week, the interference became glaringly apparent - the photos were all taken with the suspension at full droop (bike on the center stand). Once the suspension compresses, the bottom part of the chain will move closer to the bottom of the swingarm, and the interference will become much worse. When I initially had this modification done, I was reassured that the bracing was constructed in a way where the chain would have sufficient clearance AND I could retain the center stand. Well, the center stand clears but the chain does not...









I am currently working with my frame modifier to see if there is a way to resolve this issue - the first suggestion was to try a 520 chain. Unfortunately, that would require me to spend another $150 to $200 in sprockets/chain, and the overall width reduction would be around 3.3mm. 3.3mm isn't going to help this situation - other than a complete re-engineering of the swingarm bracing, I'm not sure how this is going to be solved. In any case, I have a feeling that whatever solution that we come to isn't going to be a quick one - their shop is full of bikes right now and I have a feeling my problem is low-priority.

In the interim, I decided to go to plan B - I purchased a good condition used swingarm on Ebay for $29. I spent yesterday removing the bushings, bearings, and a couple unnecessary tabs. I pressure washed it to remove the years of gunk. On Monday (8/22), it will be going to my powdercoater.



It's just money, right :-/

[philosopheriam]

On a happier note - she's almost there!

Rebuilt front master cylinder - used VHT satin black epoxy paint and gently cured in oven at 170deg (to not melt the sightglass). Used a K&L rebuild kit with a new piston.



Freshly powdercoated and reassembled calipers, brakes bled and functional, front fender installed




Rear bodywork


Overall bike

[azr]

Sorry to hear about the set back with the swingarm, ton of work into it but you'll get it sorted. Bike looks AMAZING, simply fantastic.

[philosopheriam]

Sorry to hear about the set back with the swingarm, ton of work into it but you'll get it sorted. Bike looks AMAZING, simply fantastic.

Thanks a bunch - my only concern at this point is the money I dumped into the swingarm modifications. If it can't be corrected in a reasonable amount of time, I'm afraid of getting stuck with one very expensive paperweight...

[80GS850GBob]

What's your clearance threshold on both the outside of the chain to the rear frame drop {by the rear foot peg} and inside of shock?...in other words, can you shim out the sprockets farther...say 1-2mm?

[philosopheriam]

What's your clearance threshold on both the outside of the chain to the rear frame drop {by the rear foot peg} and inside of shock?...in other words, can you shim out the sprockets farther...say 1-2mm?

It may not seem like a big deal, but moving the sprockets outward adds other complications, such as the chain making contact with one of the tabs that holds the chain guard.

The width of the chain isn't the biggest issue here - the bottom part of the chain crosses underneath the bracing on its way to the rear sprocket. The top of the bottom part of the chain has so little clearance to the underside of the bracing that once the suspension is compressed, the chain will be into the bracing.

[rudeman]

It may not seem like a big deal, but moving the sprockets outward adds other complications, such as the chain making contact with one of the tabs that holds the chain guard.

The width of the chain isn't the biggest issue here - the bottom part of the chain crosses underneath the bracing on its way to the rear sprocket. The top of the bottom part of the chain has so little clearance to the underside of the bracing that once the suspension is compressed, the chain will be into the bracing.

Anthony - Sorry to hear about the glitch.

You might be fine with the stock swinger unless you go with wider wheels and ultra sticky tires. One easy alternative to that is to use a GS1100E swinger. It's a bolt-on and is much stronger than the stock GS1000 unit. There was also some guy selling a CalFab...

[bobgroger]

How come the stuff I paint and shine up never looks that good? If you run a front sprocket with 1 or 2 more teeth will it help the clearance on the chain?