81 GS550T in Co Sprgs

[cowboyup3371]

Tonsils, adenoids, and wires

I took today off but not primarily to work on the bike. Cheyenne was diagnosed with obstructive sleep apnea a couple of weeks ago and a visit with the Ear, Nose, and Throat doctor this week pointed to oversized tonsils. Basically, on a scale of one to five with five being the tonsils touching each other, she was at a 4. Fortunately, they had a surgery time open for today (otherwise it would be until May) and she went in. The twenty minute operation went fine and the doctor told me her adenoid covered three-quarters of her nasal passages so between both of them there was probably good reason why she couldn't breathe right. She's doing better now sucking on water, popsicles, and ice cream and even talks louder without trying.

But, the day wasn't a total downer as I was able to do a few things this evening. Finally replaced the missing headlight switch with a new one and swapped out the rusted screw on the high/low beam switch



and wrapped the harness with the split corrugated wrap. I'm planning on running some tape down the split area to finish covering what the wrap didn't but I think it will work fine. I'll find out once the new connectors finally get here from Cycle-Recycle (they had some terminals on backorder).





I'm also planning to finish dipping the carbs (had one done on Tuesday) this weekend if the weather holds like they say. Once that is done and I repaint them, I don't think I'll be too far from finishing up as long as I don't keep trying to clean things.

[Good Times]

Great work Cowboy. I've been thinking about what I should do with my wiring harness. Reading your thread has "the sickness" kicking in. I will probably tear it down and replace all the connectors. I need to stop reading other build treads.

This is going to be great when you are finished with it.

[Redneck]

Glad to here the little one is doing well. What size was that screw for the headlight switch and did you use the 3/8 or the 1/2 corrugated wrap? I bought the 3/8 yesterday was looking at the wiring harness and thinking of taking it back and getting the 1/2.

Paul

[cowboyup3371]

I used the 1/2" wrap but parts of me wishes I could find a 5/8". I still have to get it back on the bike but doubt I'll have much issue.

The screw was a 3mmx6mm

[cowboyup3371]

I didn't get any pictures today but still managed to do some work. And the really nice thing was that the oldest boy (Justin, 11) finally came out on his own to help clean the carbs. Well, sorta on his own - I asked if he wanted to and he came out willingly. It was a pretty nice time and he helped me find out I needed new bowl gaskets afterall when one of them tore on us. I had hoped I wouldn't have to order them but called Ashley at Boulevard, after my local shop acted like they didn't want my business, and I'll have new gaskets and cushions for the headlight here next Monday (Yes, I know Z1 is cheaper).

So three of the four carbs are soaked and I'll throw the last one in the dip tomorrow morning. This week is supposed to be pretty nice so hopefully I will have time to paint after work. I also put the front master cylinder back on the handlebars and hopefully fixed one of my brake lines. The winds are pretty decent at 15-20 mph and a little cold to really stay outside to test it though. Also received my new connectors and will try putting them on tomorrow or so.

Definitely an enjoyable day.

[jbs80106]

Scott, you are the man and an inspiration! Makes me feel more bad for my 650 languishing in the garage for too long awaiting a 'simple' gasket replacement.....rock on man! Glad the kids are okay. All is well here too....

[cowboyup3371]

Spent time yesterday putting terminals on wires and hating every minute of it. The smaller female terminals go on pretty easy - crimp and they'll pop right out of the crimper. However, the male terminals will crimp and not come out unless I use a screwdriver and really push on them hard. Sadly, that meant I messed up about four connections and had to redo which put me short of terminals. Additionally, I realized I miscounted on what I needed (small 6-pin connectors) and then decided I should replace the coil connectors and one or two others. So I ordered more from Cycle/Recycle II yesterday and they should be here I hope by Saturday.

You might recall last year I tried to remove my air box and discovered I'd stripped the screw threads. To get the screw out meant cutting the head but the only way i could do that was to cut the bracket on the frame ending up with this:



Ultimately, I cut it off and put on a P-bracket to tide me over until I could fix it for real:



Well, today was the start of the fixing process. I picked up a new cutoff wheel for my hand grinder and a two foot piece of steel flat stock for about 7 bucks total. I then cut out a slot wide enough for a 10mm screw to fit through and grinded off the old bracket. I didn't have time to test fit everything but I think it will fit nicely. I'm hoping a co-worker gets over his bout of the bug going around here by Saturday and will weld the new bracket on. If not, I'm seriously considering picking myself up a cheap welder from Harbor Freight to do the work since he's leaving town for a new job at the end of the month.

Here's the new bracket:



And the old one cut and grounded down.



It's not the best of jobs but for my first time of really doing this stuff it wasn't too bad. I am wishing already though that I had a bench grinder so I could make that bracket look better.

[pete]

Good stuff Scott, it's always good to go back and finish of something you started a while ago, gives you a good sense of satisfaction I find.

[cowboyup3371]

Thanks Pete. Yea, it bugged the heck out of me all last year knowing it was there. I probably could have fixed it then as a guy I worked with could have done some welding on it at work. However, I didn't, and still don't, like the idea of sparks flying towards my wiring harness/fuse block/battery so I kept insisting on waiting until I had everything off the bike.

Course now that guy is gone and I'm waiting to see if this other guy can do it for me. If not, I'll probably buy a welder but really can't justify the costs right now.

[pete]

Thanks Pete. Yea, it bugged the heck out of me all last year knowing it was there. I probably could have fixed it then as a guy I worked with could have done some welding on it at work. However, I didn't, and still don't, like the idea of sparks flying towards my wiring harness/fuse block/battery so I kept insisting on waiting until I had everything off the bike.

Course now that guy is gone and I'm waiting to see if this other guy can do it for me. If not, I'll probably buy a welder but really can't justify the costs right now.

Fingers crossed he can do it for you, at least it should be a simple job for someone who knows what they're doing.

[cowboyup3371]

As my co-worker was still sick yesterday, I asked the shop where I take my truck and Jeep for service and one of the guys was willing to do it for me. So this morning, i loaded the bike up on a Uhaul trailer and he knocked it out fairly quickly only cleaning up a little bit of my grind on the both the bike and bracket. Here's the primered end-product:



I didn't have time to paint it as I went clothes shopping for a few new work clothes. but I'll knock that out this week. Course, as nice as that will look, I should tear the bike totally down and redo the entire frame


Naaaa, not yet maybe next years project.

[cowboyup3371]

Been a busy week after I get home at night spending more hours in hospital rooms than I care to (taking care of sick kids/girlfriend). Got tired of not being able to read so I also picked up my first pair of bifocal glasses finally after asking about them last year. Got the progressives and trying to get used to them; they are okay just a little annoying at times.

I received another package for connectors so I'm trying to finish up the wiring harness. Also bought and received a new Motobatt from Impact Battery. Their website said I'd pay $75 for it but they sold it to me for the price they charged on Amazon ($52) and gave me free shipping.

I also touched up the carbs with fresh paint after the dip took some off the bodies (not much) but all of the paint off the bowls. They don't look as good as last year since I didn't strip them down again but they'll do fine for now. Am hoping to get them back together tomorrow after my step-daughter and I go riding up at they Air Force Academy. I'll take Lou and we'll rent her a horse from their stables up there. At least she'll get to ride some though she'll be taking care of Lou while I'm gone.

After teaching Helena to drive the truck with the horse trailer attached today (she did fantastic), I sat down to work on the bike. Exhaust pipes went back on; had some excitement at first as the exhaust gaskets didn't fit. Seems I didn't read Z1's website very well a few months back when I ordered them. Saw today they were for the 83-85 550s and not mine; fortunately, my local shop had 17 in stock so I picked up four of them and will put the others up for sale. Then found out a bolt that had been fitting perfectly didn't want to anymore. I fit a stud in there without the collar and it fit perfectly (wouldn't last time). Once I put the collar in place though it would just spin. So I'll have to pick up a new one tomorrow.

Also getting the Jeep ready to tow the bike to Ohio; had to install a four-pin light controller assembly. This is one that has a special plug (T1 or something like that) and goes into a box with the four wires coming out of it. I'll finish that in the morning before we take off.

Pictures will follow later as I just didn't feel like taking any.

[Flyboy]

spending more hours in hospital rooms than I care to (taking care of sick kids/girlfriend).

That is not good Scott, I truly hope it is nothing too serious and strongs to them, may they recover quickly..

[cowboyup3371]

They're fine but each one of them (all 5) went through the bug that's running around town forcing each one to spend a few hours in the hospital. Mostly painful ear infections/congestion for all and pneumonia for one. I just hate hospitals period so any time I spend in one is crap for me.

After spending a great afternoon wandering the US Air Force Academy grounds on Lou (step-daughter rode a rental horse), I fixed the last stud on the exhaust pipes, reassembled the carbs (need to check the floats), and finished installing the trailer connector for the Jeep.

[Redneck]

You know Pete would say it did not happen if you did not post pictures but I will forgive you. LoL... sorry had to take this opportunity to jab at Pete. Glad to here it was just the local crud that took you to the Hospital. I miss horse riding. Been way to long, last time I did any real riding was working cows back on college break many many... well you get the picture, a long time ago.

Paul