I picked up the bike Thursday. The guy wanted $500.00 to start with but when I checked the oil and smelled fuel, I said $100.00 he countered $150.00 and said he would give me the Haynes manual and a battery tender, paid him cash on the spot. Good bike has good spark plugs, good front tire, minimal rash, minimal rust, 39,000miles. Bad, whole brake system will need to be rebuilt, carburetors will need to be rebuilt, valves adjusted, right side case badge, purple Suzuki tank stickers, rear tire, tank cleaned out due to minor rust, new handle bars, headers blasted and repainted "just because I hate seeing rust on a bike," new seat eventually because it has a few tears.

Day 1
I got the bike in the back of the truck dropped it on its side twice while trying to secure it and driving home.

Day 2- tear down and survey of true parts that need to be rebuilt.

I brought the bike into the garage and set it on a piece of carpet to prevent oil and brake fluid from marring my garage floor. Then I took pictures of the bike in some good light to document my starting point because I have a lot in store for this GS.









Next was the usual tear down for any work to be done on any GS.

Seat off



Plastics popped off



Plastics removed and set aside

Tank off and battery removed. The battery electrolyte needs filling and a proper charge before I can determine if I need a new one. I replaced the old corroded box with one off a 2000GS. You need to bent the tabs on the left side to accommodate the electrics but it went right in.



Fender removed for cleaning and ease of access to brake hardware.



Battery box and air box removed. The carbs are coming out of a rebuild and I'm contemplating on going with a lunch box and jetting.





Inspection of the internals. Everything seems to be good. Did a valve clearance check and I will need 4 between 2.55 and 2.60

On to the brakes.



Cover off.



Pads and hardware out, will be needing 2 shaft bolts.



Brake tension bar removed, mounting bolts off, make sure you loosen the caliper bolts while they are on the bracket as well. Make things easier.



Disc is within tolerance and bearings seems to be fine. I'll replace them when I need a new rear tire.



Caliper off.



Disassembled



Because I dont have an air tank at the house I used the hand held out off the red car to push out the cups.



Completely apart.



Now for the Master Cylinder.

Time for the front.



Disc in tolerance.



Caliper off.



Cups out, same way as rear.



Carbs removed.

Thats is for day 2. Now I need to get the parts to get things going again.

1 frame mounted plastics 10mm bolt.
2 rear plastic center section screws.
1 fender reflector.
1 frame plastics rubber gromit.
1 choke return spring.
2 rear brake pins.
1 rear brake support arm with castle nut.
heel guard bolts for both sides.
Crank case vent tube filter gasket
Brake pads front and rear.
1 rear master cylinder reservoir screw.
Master cylinder rebuild kits front and rear.
Front axle castle nut.
2 front caliper mounting bolts.
2 brake caliper bleeding valve screws.
4 shims between 2.55 - 2.60
1 front batlax BT45 tire
Handlebars, clutch handle.
2 Purple Suzuki tank stickers.
1 black Suzuki case badge.

thats it for now.

Good stuff. You seem like you know what your doing. Since I'm a newb when it comes to motorcycle mechanics I will keep a close eye on this thread  Good luck.

Welcome back!  Looks like you're having fun.  Motorcycles ARE an addiction, there is no cure.   

So, does the jag have Lucas electrics? 

What's the story on the street rod?

I love resurrection projects ! Please keep pictures coming 

The Jag isnt mine... Its the significant others. The red car is a Bugatti kit car. Its fun to drive.

nice project. keep us posted with pictures you could also include $$$ spent 
cheers

Quote from: Foreverunstopable on November 12, 2007, 11:20:29 AM
The Jag isnt mine... Its the significant others.

Way to catch a rich chick.  Usually it's the other way around.

waw  you know your gear and who to fix it good luck and post pics when you will finish 

looks like fun.  Are u going to repaint it?  what color?

Day 3 - Brake Caliper Clean/Prep

Well the fun parts is over and its time to sit down and clean the years of abuse out of the calipers. The cups were so bad it reminded me of .50cals coming back from the field caked with carbon deposits... The Marines prepared me to clean these parts, so have patience with them if they look bad. Just take your time, about $20.00 in odds and ends from the local store and a few hours listening to your favorite songs.

Torn completely down.



Cups caked in corrosion.






More corrosion.









The things I used to clean the parts up, most will be reused for the carb clean.



Coming out Nice!!!















Comparison of process, you take the jewelers screwdriver set and scrape in a radius around the circumference. Dont go up and down.



All done



















Time for bed, the carbs are going to get torn apart.

Glad to see you working your way back to two wheels.  Great write up by the way.  And talk about a hell of a deal...wow. 

great detail, keep the posts coming!

Quote from: Jarrett on November 13, 2007, 01:46:29 AM
Glad to see you working your way back to two wheels.  Great write up by the way.  And talk about a hell of a deal...wow. 

+1 million 

Heh,

I almost bought that bike, but decided I didn't feel like putting a ton of work into it.

not bad.  for $150, its not in too bad a shape. just needs that TLC.