1982 GS300 Project - Where do I start

[pete]

Nice... mounting should be the easy bit

[hjacobmiller]

A little bit more progress.

First, I believe that the wiring is 100% finished in the headlight bucket, thanks to Mekanix. I sent him a paranoid PM asking for help with a wiring issue. Lucky for me he is the Buddha of Zooks.

Second - I spent some time on polishing the cases this weekend. Put new gaskets and allen bolts from Z1 and torqued to 8 ft. lbs. (Spec was 6-9.5) Z1 is really amazing. I ordered the wrong bolt kit, not knowing they had one for the 300. Chris makes a list of what I need, sends it out the same day with about 400 stickers. I love stickers, in case you all have never seen my helmet. I give them to kids and such as well. Easy marketing for companies. Any ways...

Not 100% shined up like some of you gurus out there, but I don't think I wanted it to be. I think with a little bit of fuzz it will make it look clean but not spotless. I also needed to wipe it down in this pic, so it is a bit more blingy.



I also spent some time on the wheels. The pics are before they're dry, so it isn't as flat black as I would have hoped. Now, I know what some of you are thinking - "oh god,flat black, what the &%$*... sigh..." But I tried to lighten it up a little with the polishing. I also need to get new tires mounted and balance soon so I turn this into a rolling frame.

Prepped:




Painted:



Well, while fixing the wiring up I decided to go ahead and do a mock up of the headlight visor that came in over the weekend along with my Boulevard parts. I think it looks quite nice, but I still have to finish drilling out the hole for the pivot point screw.






I also carved out the throttle side bar end. It was a breeze with an exacto knife and my dremel with a sanding roll. Turner out darn near perfect by my standards.



I also mounted and wired the electronic flasher per Mekanix's suggestion. waiting for the mounting glue to dry so I can take the clamps off. Only about 3000 more hours of work to do.

P.S. I *may* I repeat *may* have passed my state board. Should know a week from today. *fingers crossed*

[pete]

I'm really liking how she's coming along Jake, and it's good to see you getting some progress! Just a little at a time will see you hitting big milestones in no time too.

I won't say congrats on the exam yet... just in case it's a bit premature

[hjacobmiller]

Well folks, it's been a while.

First things first - I passed my exam! More time now to focus on the important things, like back to the bike! Thanks for the good luck Pete - fortunately it looks like it paid off.

OK, well geez, I don't even know where I left off...















New stator.



And she starts!

[pete]

Congrats on passing your exam Jake, good news!

As for the bike... man she's lookin' good! Glad she's running again and can't wait to see her done and rolling

[Mekanix]

Holy crap! Cograts Jake!

[hjacobmiller]

Thanks Mechanix!

Wouldn't have been able to get this far without all the help you and Pete have provided.

Sorry I have been AWOL for a bit. Not much 'progress' to report since last time. I have been working a lot just like this time last year and I was waiting for a couple pieces related to the brakes to come in. I had to get new shoes for both front and back, new shoe springs, new cables and a lot of hardware...

So now I need to call on the wisdom of the GSR gurus again. As you can see in my last video it started perfectly, accelerate nicely and return to a normal throttle with no hanging idle issues. However, when I pulled it out yesterday to install all of the new brake parts, it wouldn't give me a solid start! Took full choke to get it to fire up, which for a 30 year old bike is to be expected...

But, after letting it "warm up" for a brief thirty seconds (didn't want to overheat it because obviously I wasn't riding) it wouldn't run with out the choke on.

What was even more frustrating is that it would stall every time I tried to roll on the throttle. Even just a bit!

So, the only things I have changed since the last time I worked on it are:

1. Installed front and rear brakes and hardware (guessing completely unrelated)

2. Installed tailight and license plate

3. Installed headlight

4. Installed front brake and clutch adjustment hardware.

So, needless to say I have no clue what it could be.

My thoughts are that it could possibly be unsyncronized carbs. But that wouldn't explain the change since last time since I have literally done nothing with the carbs.

My next thought was timing, but I brought out the timing light and everything seemed normal.

Any thoughts?

[pete]

Good to hear from ya' Jake.

How long has it been sitting?

I'm wondering if the fuel's started to go off and is blocking the pilot circuit?

[hjacobmiller]

Good to hear from ya' Jake.

How long has it been sitting?

I'm wondering if the fuel's started to go off and is blocking the pilot circuit?

What do you mean started to go off? Like go bad?

I mean the fuel is probably about a year old, but I would think it was just as old when it ran fine three weeks ago?

[pete]

Going off... going bad

If fuel sits for more than a few months there's a good chance it will start to go off and will start solidifying into the crap that blocks your carb passages.

I'd definitely be looking into that if it's been sitting for a year!

You'll probably find 3 weeks ago that you circulated the fuel enough to pull some cruddy bits into your pilot system.

Not sure if you'll need a full carby clean but at least take them out, take the jets out, and spray some carby cleaner through the jets and all passages.

It may still need a dip but hopefully not...

[hjacobmiller]

Hi Folks,

Just thought I'd give an update since its been a good 6+ months.

Ended up doing a dip on the carbs after these last posts. Problem solved, as usual when one takes the time to thoroughly go through the carbs proper.

Haven't done too much else with the project because I don't have a place to work on it in the winter time really. Unfortunately she sat outside all winter under a cover and a lot of the parts that I had polished up so well have gone to crap.

Have an issue to sort out with the front brake sticking a bit. Ordered a new cable and going to grease up the mechanical bits once the rain stops.

I did however take the tank to some local guys to have it derusted and sealed with POR 15. I don't have the time/space do it myself and since I want it done right I figured I'd take it to the pros. Hopefully picking it up this week and then off to the painters next weekend if I can get brake issue straightened out and pass inspection!

Cheers!

[pete]

Nice to hear from you Jake and glad to see some progress is happening

[hjacobmiller]

Cheers Pete! Good to hear from you!

Tank derusting/sealing turned out great! A little $$$, but definitely worth it to have it done right.

Dropped it off at the paint shop yesterday. Had some sweet vintage green paint and a nice cream to go with that retro vibe. Hopefully should be done by next weekend!

In the meantime, I've got the following to figure out:

1. Front brake issue. I'm guessing I just need to throw some grease on the arm that comes thru the hub, oil the the new cable and make sure the cam timing is correct for both sides.

2. Figure out what to do with the gas cap gasket. It is dry rotted to hell and there is no replacement. I ordered a new generic gas cab from ebay (from HK and cost $20 US for a whole new cap) and am thinking I will take the gasket off it and put on the old cap so I can have just one key. Thought about making one myself but the shape of the original is so weird.

3. Definitely want to get new headers made (get rid of the link bar in the middle) and new mufflers. Need to search and see what I can find.

Getting so close!

[pete]

I've got no experience with a drum front brake or a fuel cap with a gasket... but what you say sounds fair I think

Pipes... you have to get pipes just right, they can make or break the look for sure and of course you need to get them breathing right as well!

Can't wait to see some paint done

[hjacobmiller]

Slowly but surely making progress...

FINALLY got the front brake issue figured out. It just needed a bit of grease on each post coming through the hub and they release fine now. I was worried some had gotten jammed up during the last time I had the front wheel off.

Had ordered new rear shocks from MikesXS and they had the GS300 listed for a set and I ordered them. Well, unfortunately they were about an inch longer than the stock (I measured mine but through that maybe they were just so worn out they had compressed that much). There was no way I could leave the new ones on because the bottom of the shock would have busted into the muffler if my back tire went through a pothole or otherwise fully extended the rear shock.

Sending those back tomorrow. Such a pain, but better to get it done right than to have issues further down the road. Got another set that is the same as the stock.

Still waiting on an order I placed from Boulevard (now PartsOutlaw?). I ordered it almost three weeks ago and the new girl they have running the online orders isn't nearly as helpful as Brent used to be.
Any who, according to them the parts should be shipped tomorrow and to me by this weekend. Got a couple small things, nothing major but things I wanted to replace.

Have to figure out what is going on with the rear brake light. It works when I push down the pedal, but the running light is out. I changed the bulb so I think it is the wiring mechanism. That will be included in my Boulevard order when it arrives.

And now, the part you all have been waiting for. *drumroll please....*

PAINTED TANK AND PANELS!!!









Can't wait to get these last few things buttoned down so I can ride!