New to me GS1000G

[Flyboy]

Nice progress, keep the updates coming, enjoying this build.

[JTGS850GL]

Ok, today was the day to get her started up. Connected the temp gas tank and let her fill the carbs... Opps, fuel coming out the airbox. Give the carb floats a little rap with the hammer and all's well. I did remove the air filter and clean everything out again before attempt 2 on starting. All buttoned up, choke pulled, pull the clutch and hit that starter... BINGO!!!!!!!! She fires right up and surges to about 3K RPMs.. or is it 11K or 5K or 3k.

Still need to do the carb sync, but one problem reared its ugly head once it was running. The tack would jump from 3K to 11K and them back. I disassembled the tach and found this:




Obviously the tach took a good hit at one point in it's life. The inner workings looked OK but I noticed that the needle would jump and hang while rotating the tach drive.





Looked like someone else had had their hands in there since the outer ring was already buggered up from a repair attempt:


I tried to lube it up but no glory. Still sticking and lurching even when I use a drill to drive the tach. I noticed that the tach would stick more when tilted then when held face on. I'm betting that it's toast and not worth the effort to repair. At least the fuel gauge is working. Looks like I'm in the market for a replacement Tach.

There is a little smoke coming from the left exhaust but the smoke started to diminish after a few minutes of running. I'll keep an eye on that. Once it idled I did a check of the charging system and measured 14.25V at 1500 RPMs. That's assuming that the tach was anywhere near accurate. Seems like the new stator and R/R are working as expected.

Brakes are firm now as well. Ordered a petcock rebuild kit along with new plug caps. Didn't really NEED the plug caps but figured if I'm going to spend the shipping for the petcock kit from Z1 then I'll just go ahead and pad the order with something that didn't cost much but would benefit the build. I know that many have had issues with the rebuild kits but I figured I'd give it a chance since the OEM petcock for the GS1000G is around $90.

I checked the clutch and all is good there. Shifted her through all the gears and pulled the clutch in only to see that the wheel would stop spinning as it should.


All in all a good day. A little cold in the garage so I'll wait for a warmer weather to do the carb sync.

[azr]

Congrats! great progress today, always nice to hear them flash up isn't it. I sent a PM as well but I'll look around for a tach.

[JTGS850GL]

A little more progress today. Working on the fuel tank and preparing parts for paint.

Decided to go the rebuild route on the petcock since the one I had was in good condition and the price differential between new and used was $90 new to $22 rebuild. I know that many have had issues with getting the rebuild kits to work, but I decided to take it on and see what issues there were. The only problem I can see is if there is significant pitting on the vacuum driven diaphragm valve seat. I used very fine soapy steel wool (cheap Brillo pad) and was able to polish up the seat with no visible signs of wear. This is after I dipped and sonic cleaned the all the metal parts. After that I assembled the petcock with new part from this rebuild kit:


The final result was a working petcock that looked like this:






I checked all functions and everything looks to be in good working order. Vacuum diaphragm doesn't leak, the petcock flows with vacuum in both on and RES, the petcock doesn't flow when vacuum is removed and always flows when in prime mode.

Getting other parts stripped and ready for paint:


Tank stripped, scuffed and any small dents filled with Bondo:






Now I only have the last item to strip and remove the dents:



One problem area on the fender is a dent that needs to be worked out:


In the end I plan to use the PPG Deltron system for paint. I plan is to use DPLF50 Epoxy primer/sealer first with DP401LF catalyst, then a K36 sandable primer/resurfacer, then DBC base coat with DX57 activator and finally DCU2010 clear coat. I've always used PPG so that's why I'm planning on using it. If others have some better suggestions then please chime in. This is the first motorcycle repaint I've done but I've done numerous cars in the past.

[JTGS850GL]

OK, it's time to start thinking about paint and color. My plan is to use PPG as the color supplier. Basically for two reasons. I've used PPG in the past and I have a good local jobber that can supply me with what I need. Basically using the Deltron 2000 system from primer to finish clear. The big decision is what color??? I've been thinking of a nice red metallic or metallic pearl. Here's one that I was looking at. It's a Lexus paint code 3R1 and the color is called Matador Red Mica:




Not completely set on this color so any other options or suggestions would be helpful.

[SVSooke]

That or it's very close Toyota relative is the red on the 85 750

Looks quite bit darker in shady or cloudy conditions but in the sun it's just WOW!

[JTGS850GL]

No other suggestions on color?

[BluePlateSpecial]

That looks close to the Toyota Salsa red I did on my CB400-



Honestly, if I had it to do over again and I had the money I would have either done the UK spec stock cb400 candy red I really wanted or would have done a true candy.




I liked mine but it was easy to see that it was a modern color and in my opinion that just doesn't quite look right on an old bike.

[BluePlateSpecial]

I like the two-tone dark blue/green/black with a metallic silver or gold that I have seen on several GS's. I think the dark colors lend themselves well to a bigger bike but the metallic helps to break it up.

[JTGS850GL]

More pictures please. Hard to visualize the outcome with all the different colors listed.

[GSX1000E]

A bright metallic blue like the H2 Kawasaki's? http://www.google.com/search?q=H2+Ka...%3B1600%3B1200

[JTGS850GL]

I now have the engine running pretty well. Adjusted the balance and started getting the pilot fuel screws fine tuned. No more smoke emitted from the exhaust. Seems like the smoke was originating from an oil leak along the side of the clutch housing that was leaking onto the exhaust. The smoke was being drawn into the exhaust from connections that I never tightened down. Once I fixed the leaking clutch gasket the smoke suddenly disappeared. Still need to tighten down the exhaust clamps but at least I know the smoke isn't something more insidious. Waiting for a new replacement tach purchased from GSX1000E to do the final adjustments on the fuel screws, but hopefully that will be completed in a day or two.

I plan to shoot the sealer and sandable primer over the next week. Once that's done, I can mount the tank and road test the bike. I did verify that she'll shift nicely through the gears and the clutch will disengage smoothly while on the center stand. Once I road tested it I'll begin to focus on the color coat and clear coat paint. Really need the temps to rise some in order to shoot the paint. I'll post more pics once the primer is done. So far the body work looks and feels good. The PO had done a really bad job at repairing a dent in the fender which left much extra Bondo and some pretty bad metal repair. I was able to knock out the dents better and used about a pound less of filler to get it straight.

In the mean time I'm in holding pattern waiting on parts again.

[ifly85]

Great job so far. You are really motivating me to get my bike cleaned up again.

I really like your Lexus Red color.

[JTGS850GL]

Today it was a matter of getting everything ready for priming and getting the gauges put back together. Gauges now working:


Block sanded the front fender. There was a fair amount of damage but I think I've got it fairly straight now:






Changed up the primer components based on my PPG supplier. Still Using the DP50LF and DP401LF as my sealer but now using the Shop Line JP202 and JH 301 as my sandable primer instead of the K36. Much less expensive and still compatible with the DBC/DCU PPG base coat/clear coat system I plan to use in the end. Cost difference was $38 v/s $95. Just couldn't justify the additional cost when most of it will be laying on the floor when I'm done:


I'll be shooting the primer as soon as the temps get close to where it needs to be.

[Dogma]

This pic, all by itself, makes me want to get on mine and go for a ride.

I'm looking forward to seeing how that red looks.