Wandering bike then notchy front end

[Johno]

My trip to the 2011 Australian National VJMC Rally started out perfectly.

The view to the Rally site: Looking down towards Warilla on the NSW south coast.

 

[Johno]

Front end in a bad way

Front end in a bad way

Luckily I made it to the site but only just. I took it easy down Mt Keira and completed the last half a kilometre with feet down.

Something bad going on so it was into the back of the Ute and a quick trip home.

Top steering head bearing

Dry as a dead dingo's donga!

 

[Johno]

Time to get the front end off

Time to get the front end off

Replacing the steering head bearings on my 1981 GS1000G after thirty years is also an opportunity to overhaul the entire front end, refurbish the brakes and replace those OEM brake lines.

 

[Flyboy]

Nice looking G there Johno, just a reminder how we forget the "out of sight, out of mind" bits, untill they give us a gentle, sometimes not so gentle reminder that there are there too and they have now had enough of serving us faithfully.
I guess you can't complain about 30 years service from a bearing that cost the price of a six pack of tinnies.

 

[bonanzadave]

Dry as a dead dingo's donga!

Nice photos sir. Did you snap any more of your fixes ? If so, send them on to Cliff. Good tutorial. As Flyboy mentioned...Head bearing maintenance is often ignored.

Whats the story on your rear shocks ?

 

[posplayr]

Nice photos sir. Did yo snap any more of your fixes ? If so, send them on to Cliff. Good tutorial. As Flyboy mentioned...Head bearing maintenance is often ignored.

Whats the story on your rear shocks ?

That head set got a whole lot of ignoring .

I can only imagine it was not alone......................

I would think most of that pumpkin and swing arm would be due as well.

 

[Johno]

Front end rebuild

Front end rebuild

Thanks for the comments everyone.

I bought the bike new in ?81 and as far as I know the front end has never been touched.

I?m sure there are plenty others out there as well.

It is a salutary reminder to get the rest of the bike in order.

The rear shocks are French Fournales. No springs, air over oil and lighter than the originals. I run them at about 150psi. I?ll post some more photos soon.

I?ve taken photos of the tear down and will take a lot more of the rebuild.

I?ll post again soon.

 

[Johno]

Fournale Shocks

Fournale Shocks

Dave,

I've had the Fournales since about 1985/86. A motorcycle acquaintance had them on a GS1100G which he subsequently sold. He asked me if I would like to try them and I've had them ever since.

I use a high pressure low volume pump designed for mountain bike suspension and run about 150psi in them.

Air over oil. These are original and have never been rebuilt. They are much lighter than the original shocks.

I'd like to get a pair of Ikons in the near future to get a more original look.

 

[Leigh]

Johno, I saw your problem in that photo straight away.
You've got blurry bearings. They're no good.

Remember your eyes late on a Friday night out?
Same thing..
Blurry bearings, bike wobbles.
Blurry eyes, you wobble.

Trust me, I know things.

 

[Johno]

Bearings

Bearings

Thanks Leigh.

Just keep taking the medication and those pictures will clear up.

 

[Johno]

Front end tear down

Front end tear down

The front end dismantling commenced with the removal of the front wheel and chrome front guard (fender). Speedo and tacho cables and headlight shell.

and handle bar cover,bars etc.

 

[Johno]

Wiring in the headlight shell

Wiring in the headlight shell

Wiring in the headlight shell was progressively labeled as it was disconnected.

 

[Johno]

Front end freshen up

Front end freshen up

The replacement of the steering head bearings turned into a full on front end freshen up.

The calipers and brake lines were original and apart from changes to the brake fluid had not been touched since leaving the factory.

New OEM parts - seals, caliper pin boots, brake pad springs and keepers, bleed nipples were ordered from the local Suzuki dealer. All were available within 24 to 48 hours.

HEL Steel braided brake lines arrived from Brisbane overnight.

The alloy parts on the triple tree, headlight brackets, clutch lever, handle bar keepers and brake calipers were prepped and sprayed with VHT caliper paint ? mat black - and baked in the oven late at night.

 

[Johno]

Painted items

Painted items

I used satin black VHT caliper paint on the various triple tree parts, calipers and clutch lever.

 

[Truth]

Nice! Keep the pics coming please!

 

[Johno]

Caliper with 30 years of crud

Caliper with 30 years of crud

This is how the calipers looked when they came off the bike.

 

[Johno]

Cleaned up and prepared for paint

Cleaned up and prepared for paint

The calipers were cleaned up with 160 and 380 grit.

Lots of compressed air to get rid of all the dust and finally grease and wax remover.

 

[7981GS]

They look real nice in your second Before picture.

Daniel

 

[DanTheMan]

I like what I've seen there, especially the recycled voting booth for a paint booth!