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A forum for stories, pics and updates of your resto's. Be it a barn find, Grampas hand me down or a bike being brought back to it's former glory.If you are restoring it, show us your stuff!

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sos
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Re: Gold Member

#196

Post by sos »

By getting the upper steering stem bearing I was able to get the steering stem adjusted to fit the GL frame.

First I had to get the old bearing race out of the frame.
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Then set the new race and figure out out how far to press the stem further into the lower tree.
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It still needs to be welded, but it is good for test fitting.
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2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Location: The Flatlands of NW Ohio

Re: Gold Member

#197

Post by sos »

Next task on getting the front end sorted is to get the front axle made up. I’m going to use the stock axle and machine 2 bushings to weld on each end (one on the axle and the other on the nut). That way I can use stock bearings, speedo drive, etc.

Fortunately the with is nearly identical to the GSXR and the width where the forks clamp is also nearly identical. That makes it much easier to modify the stock axle.

The axle needs to be in place so the wheel can be centered and secured so I can really see what offset the rotors will need.

The issue with is the stock spoke wheel looks like getting the calipers to clear the spokes.

So far the rotor off set is very close to what it needs to be.
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2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Location: The Flatlands of NW Ohio

Re: Gold Member

#198

Post by sos »

Well I hit the first pothole on this build.😞

Started cleaning up the GL1100 motor to get ready to prep it to go into the GL1000 frame. There was a lot of oil on the left side under the cylinder head. When I cleaned it off there was epoxy near the front starter bolt. No bolt.

Pulled the starter and removed the epoxy and there is a weld repair where the bolt hole used to be.
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Probably someone tried to put the wrong (too long) bolt in there and cracked the case.

Not sure if the epoxy did anything. There is a lot of oily residue on this side of the motor but it is all over, further forward and higher. Probably a valve cover or head gasket leak.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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Whiskerfish
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Re: Gold Member

#199

Post by Whiskerfish »

"Usually" oil leaks from that area are the shifter seal. Easy-peasy fix.
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sos
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Re: Gold Member

#200

Post by sos »

I’m sure we can make it leak free. My buddy next door is an excellent welder and has probably welded 100 case cracks.

I don’t know how the replace the bolt hole for the starter bolt without completely splitting the cases. I don’t think it is worth it to worry about that second bolt.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Re: Gold Member

#201

Post by sos »

Continuing on with the 1100 motor. I know that the GL1100 ignition at the rear cover won’t fit into the GL1000 frame, but I couldn’t tell from the parts diagrams if I could just remove it. I was afraid it ran off an idler gear or something. Fortunately it was not an issue.
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It came right out. All I have to do is plug the hole in the rear cover and all should be well😁
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2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Re: Gold Member

#202

Post by sos »

Jumping back to GM Jr,

It has been running well. I have about 200 miles on it since putting it back on the road.

One of the left carbs will stick a float shut every once in a while, but it frees up after a couple minutes.

I did put in #40 pilots and did the air jet mod. It runs really well at idle, just off idle and after about 1/4 throttle, but between 1/8 and 1/4 throttle it is almost completely flat. Get a bit annoying to ride.

If I run it with the chick 1/2 on it pretty much clears up and has good throttle response.

It has #62 primary mains and #120 secondary mains right now. Going through my old stock I found these.
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They are #70 Primary Mains that I used to source from Sudco. I probably had them for all the CB/CL 350 twins I used to do.

I can’t remember what I used to run in my 1976 GL, but I definitely need more than the #62s that are in this one. Hopefully #70s aren’t too much.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Re: Gold Member

#203

Post by sos »

Had a chance to swap those primary main jets to the #70s.

Haven’t had a chance to road test it yet so I won’t know how it did for a day or so. If I had them available I would have gone with #68s, but at least in the garage it runs and revs good.👍

I took the chance to clean and check the slides and caps. They all looked pretty good, but there were two that were very slightly sticky. Cleaned those and they all slide smoothly now.

I was pretty happy with the way the bowls looked when I changed the jets.
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All 4 bowls looked about the same. Considering how rusty the tank was when I started I’m happy with how clean the fuel is. That’s right at 200 mikes since I got it running.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Location: The Flatlands of NW Ohio

Re: Gold Member

#204

Post by sos »

Got a short ride in yesterday and so far those #70 primary jets are good. It has a nice steady feel all the way through the throttle now👌

I also tackled a project I was dreading 😬. Replacing the stock bars with super bike bars. Changing bars isn’t bad, but drilling out the new bars and getting the wiring through them is a pain.

I feel much more in control of the bike with a lower bar.
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Feels much better to me now.

Next project for this bike is making shorter throttle and clutch cables and a new upper brake line.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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Fred Camper
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Re: Gold Member

#205

Post by Fred Camper »

I put superbike bars on BADDOG and love them, perfect for a city and highway balanced ride.
Proud member of the NGW Cartel (Rochester MI)
1977 GL1000 BADDOG (April 2012 BOTM)
1976 LTD - '993 LTD...and so it begins'

You should remember that it's peace of mind you're after and not just fixing the machine. R.Pirsig
sos
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Re: Gold Member

#206

Post by sos »

Fred Camper wrote: Sat May 07, 2022 8:58 pm I put superbike bars on BADDOG and love them, perfect for a city and highway balanced ride.
I really like them as well, however I found that my mirrors are absolutely useless now. Gotta change that🫣

I had bar ends on my 1976. I don’t want to just copy that bike, but they did work well and I thought they looked good too.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Re: Gold Member

#207

Post by sos »

We had to head out of town for a week or so. It was an unplanned delay to goldwing progress. I still haven’t been to the shop, but I did have some progress before the break that I didn’t post.

I knew the water pump on the GL1100 motor needed to be replaced. It had noticeable play in the shaft. So I ordered a WP seal kit and pulled the front cover.
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Looks like there are a few ball bearings missing 🤔
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Re: Gold Member

#208

Post by sos »

I have to say I don’t know where the ball bearings went 😗

I thought I would pull the WP from the GL1000 motor, but when I got that cover off the bearings were rusted up.

Since I have 2 water pumps that aren’t any good as is I think I’m going to rebuild them into 1 good one. I hope😬

I pressed the one apart to see what parts were involved. There is really not mush to them. A mechanical seal and 2 sealed roller bearings. That’s it.

The mechanical seal from the GL1100 is in good shape. The ceramic seal in the back of the impeller is good and the spring loaded seal is good too. I haven’t pulled the other pump apart yet, but I know the bearings are available and the mechanical seal is available too if I need it.

When I get back to the shop I’ll pull the second pump apart, get the housing stripped down and order the bearings.

Also, my buddy with the fab shop next door came back from his vacation and looked at the case crack at the starter bolt. He said it wouldn’t be any issue to repair the internal boss, drill and tap a new hole and it would be good as new. It would be a different story if this motor was still in a bike 😝
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Joined: Sat Jan 02, 2010 6:55 pm
Location: The Flatlands of NW Ohio

Re: Gold Member

#209

Post by sos »

Been busy the last couple weeks, but I had a chance to get down to the shop this afternoon.

I had picked up new SKF bearings for the water pump from a local bearing house last week and finally did the water pump today.
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Got the front cover, pump and associated parts cleaned and sand blasted. Had to remember how the pump went back together.
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First bearing pressed in.
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Then the mechanical seal and housing.
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Finally the pump shaft, spacer and backside bearing. Then there is a small circlip to hold it all together.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
sos
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Posts: 146
Joined: Sat Jan 02, 2010 6:55 pm
Location: The Flatlands of NW Ohio

Re: Gold Member

#210

Post by sos »

After sand blasting the front cover and associated parts I painted them to keep the oil and dirty fingers off the aluminum.
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The rebuilt water pump installed and the New seal kit in place, I am closing this end up.
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I still need to get the case repaired at the starter bolt, but my buddy is at Road America for the race this weekend, so that will have to wait. I can get the rear cover buttoned up. I need a soft plug to fill the hole for the ignition drive shaft and make a cover and gasket to seal that up.

Also, I did get the shift shaft seal and the washers / shims to finish setting the steering stem. I’ll see how much time I get to go to the shop.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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