1979 GS1000L build

[sschering]

Somehow somewhere I lost the thread I had going in the GS Owners forum..
Guess I'll start a new one here..

The $100 wonder bike.. If I only knew the trouble hidden inside..

It's seen a few changes along the way..

 

[sschering]

I'll try to just post new things and not rehash how I got here.

I mounted a FH008 Rectifier/Regulator where the old Regulator goes.

First I made a mounting plate for it

It fits OK but makes accessing the solenoid a PIA. Turn signal relay is a bit crowded but it'll live.

 

[sschering]

I got a box of goodies from Z1 today..
530 chain, sprockets and new front wheel bearings.

 

[sschering]

Turns out the only way to replace the neg battery cable is to remove the cabs and air box.. It sucks but it had to be done since the PO had spliced the cable.

I got to use my new crimp tool last night.. This thing is awesome!

One shiny new brass open barrel bullet connector.

Wire stripped, crimper loaded.. time to squeeze!

The finished crimp looks like it came right from the factory.

I got all the rear turn signals wired up.

New connectors for the Rectifier/Regulator

 

[coastiepete]

I'm getting tired at looking at your posts. They are everywhere! Lol

 

[1978GS1000custom]

I'm getting tired at looking at your posts. They are everywhere! Lol

yea but ya got to love the pictures... nice buy! let me know if ya need help.cliff

 

[sschering]

I'm getting tired at looking at your posts. They are everywhere! Lol

hehe I gota spread the love People outside the PNW might be interested too..

Your build is turning out way cool..

 

[Go Mifune]

I must ask. Where did you get it and how much? Not the bike, the Crimp tool?:?:

 

[sschering]

I must ask. Where did you get it and how much? Not the bike, the Crimp tool?:?:

Vintage Connections..
http://www.vintageconnections.com/
It's at the bottom of the price list page, Section 10 Hand Tools
RTL Crimper $35

You can also get the crimper in one of their repair kits.

If it matters the new wire I used is TXL wire. It has OEM looking tracer lines and insulation good to 280?f. The same wire GM uses in it's new cars.
It came from EFI Connection
http://www.eficonnection.com/eficonnection/wire.aspx

 

[sschering]

Small progress. Chain on and riveted. Looks like I should have gone with the 114 link chain..
I'll probably knock off a few links later but I'll need a new master link first.

I got bored waiting on some parts soaking in the carb dip and killed time by polishing the crush drive and spacers.

 

[sschering]

Just a few setbacks..

The Garage was flooded from a slow driveway drain and my wife's aggressive all day lawn watering campaign.. No big deal.. she did it last year too so I already had most things up off the floor or in plastic tubs. It just takes forever to dry out..

I got e-screwed..
I won a GS1000L tank on Ebay from a seller with good feedback.
2 days after the auction ends the seller started racking up tons of Neg feedback for non-delivery and no response to messages..

So I guess the fight is on to get my $$ back..
We'll see how good Paypal buyer protection is.

Enough ranting.. I got a new set of buffing wheels and plan to take on the corroded chain cover.

 

[bigbill808]

Can't wait to see the finished project!! Looking good so far.

 

[sschering]

Man I haven't updated in awhile..

I'm getting close to firing up the bike..

All the electrical work is done.

Tank has been de rusted and had the rear tab welded back on.

This weekend I pulled the forks (AGAIN!!) to install new seals..
I got a bit carried away and it's turned into polishing the lower legs..
I'm almost done with that.. I'll roll it out tomorrow and take pics..


Now my hands are sore from sanding and buffing for hours

I got a bit inspired by ScottyChop's drilled rotors and drew up a template for my GS in Sketchup.. It's a non directional Brembo pattern so I can't screw up the left or right side

 

[sschering]

I don't know why my bike spends more time like this than on it's wheels..

Not perfect but a hell of a lot better than old pitted yellow clear coat.
It only takes a few hours to strip, sand and buff em out. New seals and wipers installed..

 

[sschering]

I wonder what else I can polish.. Those calipers are looking sad now..

 

[sschering]

Good progress today..

Bled the front brakes with a little help from the kids.
Went over the bike with a torque wrench making sure it's all snug.
Put the cotter pins in the axle nuts.
Changed the oil and made a new adjuster for the choke cable.. The old one went MIA..

I got it outside and fired her up..

There was a lot of oil smoke from the right side at first but it's decreasing..
I'm thinking the rings may need to re-seat after it's multi year snooze..

She's running well for a first fire up but needs a little tuning..

While it was running I checked the FH008 R/R I'd put in before..
Battery was 12.8v with the bike off.. 13.95 at idle and 14.05 at 3k..
I couldn't ask for better than that.

 

[Nessism]

Nice work. Gotta love these threads with photos. Looks like you've got trouble brewing; that daughter of yours looks to be taking a top speed run (in her imagination). Good luck with that in about 10 years.

 

[scottychop]

How's it coming?

How's it coming?

Thanks for the rep man. Did you end up drilling the rotors? Progress?

 

[sschering]

I didn't drill them yet.. I'll happen soon but I really wanted to get out and ride..

I took it for the first ride tonight.. Yeah I know maiden voyage in the dark isn't the brightest idea but it it ran 90% flawless..

The petcock rebuild kit isn't here yet so I'm just keeping it below reserve so I can turn the fuel off..

First milestone was getting to the gas station.. I wasn't sure if it would make it with the tiny amount I'd put in the tank for tweaking the carbs.

It took a bit to get used to the riding position with the rear sets and clubman bars but after I got rolling and settled in it's quite comfortable..


I didn't play much.. It still needs a little work.. I have an oil leak at the head where the cam chain tunnel is.. I suspect the O ring is bad so now the head has to come off.. It'll be a good time to check the valve shims too.

The tach is sticky.. It lags by about a minute so it needs to be stripped and cleaned..

Front brakes are soft. Must be a stubborn air bubble in there somewhere..

So with despite all the little thing it's a freakin awesome ride!!!


Looks wise it's a like a gender confused cafe/cruiser mix. The back half just isn't working with the front.. Over the winter I'll try to make a tail cowl that blends in with the seat and eliminate the rear fender. That or try to make my 78 GS1000E seat and tail work on this frame.. I don't think that front fender is really working either..

 

[sschering]

A few months later nothing much exciting has happened.. I've taken the bike out on a few weekends and done some photo tag with the local riders but that's about it..

I finally got the petcock rebuilt using a kit from http://www.carbkitscapital.com..
I can't remember the manufacturer.. Tour-something.. Anyway.. It was the only one I found that was specific to the 79 GS1000L..
Perfect fit.. 0 leaks.. My only issue was that it wouldn't close.. It'll do that now..
Finally I can fill the tank.. Yes the fuel gauge works!!

I took it to work for the first time today.. First time I've done that since I broke my Yamaha in May.. Mostly because I usually take the 4yo to daycare..

The trip was uneventful except the stupid oil light started flickering right after I wound it up going down the highway on-ramp..

I took it easy to the next exit and found this.. (see pic)
I must have knocked it off when I was adjusting the idle.