1982 GS300 Project - Where do I start

[nelson]

I like it a lot! LOOKING GOOD!

I'm working on a GS300 myself right now, and mine looks really rough in comparison... Bare metal tank and bike didn't come with panels... That paint came out really nice!

Let's get that thing on the road!

[pete]

Excellent Jake! That paint job looks awesome!

[hjacobmiller]

Cheers guys!

Pretty excited. Received the knock-off gas cap from China this week, the extra shocks and FINALLY got my order from Boulevard!

Any suggestions as to why the tail light may not be working but the brake light works fine? I know it is a combo bulb, but I put a new bulb in but still no luck. Just put on a new brake light switch so that isn't the issue. Looking at the schematic it looks like it might be something in the ignition switch?

Other than that I think the final touches should go pretty smoothly tomorrow to get it back up and running. I know I will need to get the tail light fixed before inspection, but hopefully everything else should be fine!

More pictures tomorrow...

[pete]

Good stuff Jake!

Are you doubly sure the bulb is the right one? I seem to recall something funny with bulbs in mine and I didn't have the right dual filament one, but that was way back in about '98 or '99...

Can't wait to see her all in one piece!

[hjacobmiller]

Drummmm rollll...............

So, been a while since I've been on here. Unfortunately not much has changed on the bike, and it has not been ridden much due to a couple of reasons. First, have not taken the time to maintain it correctly (tsk tsk! no wonder my forum level has dropped to Newbie) and the carbs have gunked up, fuel gone bad, battery dead, etc. This is mainly because of the second reason, which is that I have added a few horses to my stable (a garage now instead of an apartment parking lot). A 2015 Triumph Scrambler, 1986 883 Sportster (inherited from Grandfather) and a 1974 Honda CB125 (inherited from a family friend.)

But, I am back to tinkering on the Zuke!

My first move was to cut the stock exhaust cans off because it just isn't breathing right, and hasn't been, ever. Even it's best of days running a couple years ago, it always felt bogged down. So, a quick trip to Harbor Freight, $30, and a cutting wheel later, the cans are cut off with enough of a stub to put some other slip ons (probably EMGO 12" Shorty). (pics later tonight).

With my new found friend, the cutoff wheel, in my hand, I'm reaalllly tempted to start tearing in to the seat mounting points to get at mounting a flat "brat" style seat... But, if my millions of hours spent on the GS Resources have taught me anything, it is to learn first and cut second.

Does any one have a good post about attaching a flat seat? I have a material in mind for the pan, but really can't put together an idea in my head about how to attach, especially at the front where the hideous "L" king and queen slides over to cover the tank mounting bolts.

More pics later about what/where I'm thinking about cutting, but I'm just so anxious to get input I couldn't resist posting on the lunch break.

Appreciate anyone still subscribed to this thread. Really looking forward to getting back into this bike. They say you never forget your first...

Best,
J

[pete]

Mate glad to see you're alive! I was just thinking of your 300 the other day and whatever happened to it...

Can't help you on your seat unfortunately, I'm still running the stock pan on mine and when I make a custom pan for it soon it will stick use the stock mounting setup. By custom I just need to make it a solo seat as insurance is a hell of a lot cheaper here.

How does the Scrambler go? I got a thing for those...

[hjacobmiller]

Good to be back, Pete! Your bike/craftmaship is still the standard I hold my work to!

So, here is how I want to modify the frame:



Cut the stock seat support away, and then bolt a strip across the back where the turn signal bracket mounts are. Then, I can put a single mount in the center (center hole) for the fender which I plan on "bobbing" back significantly. The two holes on either sides would be for the seat pan. The side bolts on the fender would be unchanged and provide the same support so the fender doesn't rock to and fro.

Does removing the stock seat support cost me any lateral support? I know a lot of folks will weld hoops on the back, but not really an option as I don't know how to weld or have a welder. Is it dangerous to remove this?

The part I'm really having trouble with is the area at the front, which I have no idea how to do tastefully. I'm not opposed to leaving the tank mount bolts exposed, but then I don't know how secure the front of the seat. The stock seat has a tongue/fork set up so that the "nose" of the seat slides over the tank mount. I'm just having a mental road block.



Any suggestions?

The Scrambler is a blast Pete. A big step up from 300CC to 900CC, but what a difference in comfort and can't replace the reliability of fuel injectors! Although, it is a whole new type of scary when it comes to tinkering though. PM me if you want a link to my Triumph forum thread (which hasn't been updated in a while since I've been riding too much to type!)

Thanks,
J

[pete]

When I initially was planning my build, I also planned on removing that seat brace before deciding to stick with the stock pan and lock setup.

What I did find out though is that piece of steel does nothing for frame integrity and does not appear to do anything except give the seat pan a place to rest on. Someone posted a Youtube video at some point of someone grabbing one that had been cut off and twisting it in their bare hands, so that's not going to provide any structural strength at all.

As for the front, can you get a pic of the bottom of your seat pan?

My suggestion is do something to cover those tank bolts... if you do manage to slide forward off the front of the seat for some reason... well...

And yeah shoot me a link to your Scrambler thread for sure! They do look like a hoot although I think I'll be sticking with my old Zuk's for a while yet. My Kat is my dream bike so she should keep me satisfied for a while

[hjacobmiller]

Bending in your hand? Jeez, I didn't realize it was that flimsy! Good to know that I won't lose any thing by getting rid of it though. Thanks for the input.

Here is the front:





Not sure how to replicate that. I'm planning on using some large composite cutting boards I found at Walmart for about $6 a piece as a pan.

I just really can't think of an aesthetically appealing way to attach to the front! I keep getting hung up on how to attach it while having the front of the cover be stapled down to the pan.

On a side note, my buddy just picked up an 82 GS450 for $80! Looks like there is a lot missing and the engine is possibly seized. If he can't get it to run, he's going to part it out. The tank is clean and not dented though so he'll be able to get his money back probably with that alone.

Why I'm even bringing this up is because it has spoked wheels and a front disc brake... Methinks I could grab the hubs, forks, and calipers from him and have a disk brake on the front.... I'm assuming the hub is the same width and the axle's are the same, would have to look at part's fiche. This way I could get the awesome symmetrical wheel look and upgrade the braking capacity...

Thoughts?

Pete, I think you're the only one I'm talking to haha.

[pete]

I guess the big question is what are you trying to achieve? If you just want a lower profile seat, then maybe just trimming the foam on the stock pan will work?

If you want an absolutely flat seat, then yeah that gets a little tricker...

However, it looks to me like if you use the rear mounts on the frame for the rear of the seat, it's going to sit above the frame rails a similar height to those mounts at the front anyway, so maybe replicating that front mount setup is the way to go.

You could always mould some fibreglass around the mounting posts on the frame (make sure to use a release agent!) and attach that to your seat base... or you could just make the seat base out of fibreglass.

I can't offer a lot of tips in this area just yet because I haven't even started on mine...

As for the front end, yes there's a very good chance it's a direct swap. Looking at the triple clamp parts numbers on the fiche may give you the answer there, or maybe even just checking against the steering head bearing part numbers.

[hjacobmiller]

Checking in...

Still haven't figured out the seating arrangement, but have done a little bit of tinkering here and there.

1. Recently purchased pod air filters and removed the airbox. GASP! How dare he?!?!? It will be a nightmare to dial in...
Pods are K&N RC-1060. Inlet measurement ~50MM. $21 USD/each
2. Purchased Six 6 Jet Kit and just finished installing the shims on the needle. Piece of cake and everything else is just a direct screw in swap for the other jets.
$55 USD shipped. Really fast shipping and seemingly easy to install. I don't know the running results yet, but will review once complete.
3. Running into trouble with the kickstand/centerstand with the EMGO shorty's. They're just a bit too fat to let the stands close completely. More to come.

Might throw some pictures up later.

Cheers,
J

[pete]

Good to hear from you! Would be better with pic's of course

Interested to see how you go with the jet kit... many mixed reports from there.

For the stands, you can always add a larger rubber stopper depending on how low they're getting held down. You don't wanna scrape them in left handers...

[hjacobmiller]

Back after another hiatus...

Scrapped the EMGO shortys. Too much of a pain. Made a "custom" exhaust with some 1.625" pipe, internal baffles and VW exhaust tips...











Was going to buy a welder and teach myself, but unfortunately don't have sufficient 20 amp circuits in the garage. Fortunately a neighbor up the street (who has an amazing KZ1000) has previously offered to do some work for me.

Just need a couple beads at the joints for this, although with how tight the I/D of the straight pipe and O/D of the headers fit, it may not be necessary.

Took a short video:

http://vid1256.photobucket.com/albums/ii481/hjacobmiller13/IMG_1572_zpsdfafpxlf.mp4

[hjacobmiller]

Also, relocated the R/R and starter solenoid to the battery "box." Made all new starting/primary circuit connections and routed wire more cleanly, IMO.





Eventually this "tray" will get plasti-coated and house the motogadget munit, and I'll be able to get rid of the rat's nest of wiring currently ziptied to where the headlight should be...

[pete]

Glad to see the 300 being worked on again! Nice work, and those pipes have a nice rorty sound to them... I like it!