The '82 GS1200G project

[Planecrazy]

So far it looks like the shed wall is about ready to "go go go!"

You do, indeed, have your work cut out for you to make Bruce's rally ... but it's going to be a sweet ride - Looking good so far!

Hope the base gasket "fix" proves reliable ... it would suck to have to go back in later but I've had a lot of success over the years with "form-a-gasket" on various types of engines, so I'm cautiously optimistic you'll be good to go - crossing fingers and knocking on fake wood for you!

Regards,

[7981GS]

Got the valves adjusted (miles out of adjustment), finished polishing/painting the rear wheel,
mounted the new tire and threw some parts on it to get the idea...




Daniel

[Planecrazy]

Got the valves adjusted (miles out of adjustment), finished polishing/painting the rear wheel,
mounted the new tire and threw some parts on it to get the idea...




Daniel

I see you're going to have to fix that 1100 badge, hehe!

[7981GS]

Anyone know where to find some GS250 side cover emblems to steal the 2's from?
I would rather not use stickers.

Daniel

[Darin Jordan]

I like the black painted case sides... I may have to do that to my 850 the next time I have them off. You are right, it looks good against the silver motor, and it's definitely a little different.

[7981GS]

Not nearly as much progress as planned today but, I did make some.

Cleaned up all three rotors, rebuilt the rear caliper and changed the close to worn out pads:



Mounted rear caliper/rotor and torqued the rear axle:



Just so that everyone gets a better idea of the condition of the bike when I got it,
these are the old covers that I chose not to re-use:



Finished polishing/sanding the front rim and got it painted a few coats:



Draining what little oil that was in the forks over-night.
And partially got one front caliper rebuilt.
Cleaned out and got the front master cylinder working.
Stripped the paint off of one of the foot-peg mounts with wire wheels on a die grinder.
Called on the last remaining/missing H-D parts for the Panhead project a couple of times
after being told that they would be done Friday and that they were done Saturday...
"They are still working on them." was today's out-right LIE!
Someone who is also trying to join Renobruce's WS Rally is counting on riding his bike there.
4 weeks for a 2 hour job!!!!! 4 valves/guides/seats in 2 heads.
His engine, would have been RUNNING 3 weeks ago!

Daniel

[7981GS]

When I went to pick up the mounted front tire this morning, I spotted this Gem in the back of a truck parked there:






Rebuilt the forks. It already had progressive suspension springs in it.
As it still didn't have enough preload for my taste, I cut two 1/2" pieces of schedule 40 PVC pipe and added one 3/8" flat washer to each tube.
Filled each with 525ml of Amsoil 10W fork oil. Pic of spacers:



Tomorrow I will finish the other front caliper and mount the forks, brakes and wheel.


Daniel

[Flaming Chainsaws]

This will be a sleeper for sure! The engine and wheels look great! See? You don't need me to do your wheels .

[7981GS]

Got most of what was planned done today with several snags along the way. (Of course.)
The PO had replaced one of the fork axle studs with a bolt. As I didn't have the correct
length stud, I cut a grade 8.8 stud down to fit after re-tapping the threads, etc.



While re-building the speedo drive, I found the drive teeth worn and practically gone
at both the driven side and the axle side.
I pulled a couple from a 650 apart and used the best that I had for now.
The center one, is the one from the 1100G. I used the one on the left
with the most material left on it.





She is now mobil and tomorrow I will try to install the engine and re-bleed all of the brakes.



Forgot to add that the steering head bearings and races were trashed also.


Daniel

[7981GS]

Plenty of more bolt holes to re-tap and bolt threads to clean, every time I turned around!
After attempting to polish the oxidized/scratched foot-peg mounts, I gave in and painted them (before painting):



Managed to pull the engine off of the stand and outside:



Placed the engine on my tranny jack and scooted it over to the frame with a floor jack and lumber waiting:





Just walked the engine right over and dropped the floor jack to meet the mounts.
Doesn't look like nearly the amount of work got done:



Tomorrow, the carbs, turn signals, headlight, etc.
Wiring with GSexpress' expert wiring help.
Without his help, I doubt that I would have a prayer of a chance to get it running any time soon.


Daniel

[chef1366]

Plenty of more bolt holes to re-tap and bolt threads to clean, every time I turned around!
After attempting to polish the oxidized/scratched foot-peg mounts, I gave in and painted them (before painting):



Managed to pull the engine off of the stand and outside:



Placed the engine on my tranny jack and scooted it over to the frame with a floor jack and lumber waiting:





Just walked the engine right over and dropped the floor jack to meet the mounts.
Doesn't look like nearly the amount of work got done:



Tomorrow, the carbs, turn signals, headlight, etc.
Wiring with GSexpress' expert wiring help.
Without his help, I doubt that I would have a prayer of a chance to get it running any time soon.


Daniel

Don't sell yourself short Daniel?
I'm probably going on my maiden voyage today.

[7981GS]

With it real close to 100 degrees outside, it was nice to have the option of bringing it inside in some shade.
Made a little more progress today. GSexpress figured out most of the electrical nightmare and here is where we are at.
Sorry for the crappy pic's. It is dark out and not much lighting in the shed:








Daniel

[7981GS]

Still have more work to do to it but...

http://www.youtube.com/watch?v=ZnwIIKnWJtg

Daniel

[MiloBramble]

Nice looking re-build.

[7981GS]

The front fender that I had planned to put on it DIDN'T FIT!!!
Then, I tried 2 chrome ones that also DIDN'T FIT!!!
I had to use this scratched up, lighter colored blue one that someone had modified in the past... that DID fit.

The rear mounting holes on the first 3 were higher on the fender cross-brace making them too close to the tire. WTH?
I never had this problem before perhaps it has something to do with the '82 being an 1100G?





Tomorrow, I try to make the exhaust from another '80 G work, fix the rear M/C, add body parts, test ride and change the oil.

Daniel