Gold Member
Moderators: Brant, Sagebrush, Forum Moderators
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
Summer is a tough time for projects. Too much to do and not enough time
Motocross season has kept us busy and I did get slightly sidetracked with a 1971 BSA Lightening project.
That is pretty much done and being ridden now so back to the GM3.
I got the front of the GL1100 motor back together with the rebuilt water pump, got the 77 cams and rockers switched over the 1100 motor and was getting to the point where I needed to get the case repaired before I could move forward. That finally happened today.
The old repair from what I thought was someone putting in a starter bolt that was too long. Turns out it was just epoxy filling the hole and the hole was much bigger than I thought.
We had to build the surface up to get the starter mounts to sit flush. Then once we got to clean aluminum there were two big cracks propagating from the hole. Fortunately this was not the first repair my buddy has done.
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Now that there is new aluminum where the JB weld was and there is actually a threaded hole to mount the starter, I can continue prepping the motor to put in the frame
Motocross season has kept us busy and I did get slightly sidetracked with a 1971 BSA Lightening project.
That is pretty much done and being ridden now so back to the GM3.
I got the front of the GL1100 motor back together with the rebuilt water pump, got the 77 cams and rockers switched over the 1100 motor and was getting to the point where I needed to get the case repaired before I could move forward. That finally happened today.
The old repair from what I thought was someone putting in a starter bolt that was too long. Turns out it was just epoxy filling the hole and the hole was much bigger than I thought.
We had to build the surface up to get the starter mounts to sit flush. Then once we got to clean aluminum there were two big cracks propagating from the hole. Fortunately this was not the first repair my buddy has done.
.
Now that there is new aluminum where the JB weld was and there is actually a threaded hole to mount the starter, I can continue prepping the motor to put in the frame
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
- Whiskerfish
- President
- Posts: 36964
- Joined: Thu Feb 16, 2006 9:34 pm
- My Album: http://www.ngwclub.com/gallery/v/wingmans/whiskerfish/
- Location: Norfolk Va
Re: Gold Member
Nice work!
"Agreement is not a requirement for Respect" CDR Michael Smith USN (Ret) 2017
"The book is wrong, this whole Conclusion is Fallacious" River Tam
"Yea I do dance awkwardly, and I am having more fun than you" Taylor Swift
2008 GL1800 IIIA "TH3DOG"
1984 GL1200 Standard
1975/6/7/8/9 Arthur Fulmer Dressed Road bike
1975 Naked Noisy and Nasty in town bike
Psst. oh and by the way CHANGE YOUR BELTS!!!!
"The book is wrong, this whole Conclusion is Fallacious" River Tam
"Yea I do dance awkwardly, and I am having more fun than you" Taylor Swift
2008 GL1800 IIIA "TH3DOG"
1984 GL1200 Standard
1975/6/7/8/9 Arthur Fulmer Dressed Road bike
1975 Naked Noisy and Nasty in town bike
Psst. oh and by the way CHANGE YOUR BELTS!!!!
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
My buddy hooked me up showing me how to cut the bushings to adapt the GL1000 front axle to the GSXR forks.
We found a scrap piece of steel in the bin, cut the OD to match the GSXR axle, then drilled out the center to press onto the GL1000 axle end and nut.
This allowed me to center the wheel and see if the calipers would clear the spokes. I knew it would be close, but it can’t get closer than this.
It does clear and once I find 320 to 330 mm rotors to fit I’ll shim the calipers to center them.
Now that it is actually a rolling chassis I could mount the motor.
We found a scrap piece of steel in the bin, cut the OD to match the GSXR axle, then drilled out the center to press onto the GL1000 axle end and nut.
This allowed me to center the wheel and see if the calipers would clear the spokes. I knew it would be close, but it can’t get closer than this.
It does clear and once I find 320 to 330 mm rotors to fit I’ll shim the calipers to center them.
Now that it is actually a rolling chassis I could mount the motor.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
Glad to finally get the motor back in the frame.
This is the GL1100 motor in the GL1000 frame. It has the 1977 GL1000 cams, rockers and ignition.
Here’s what the GL1100 motor looks like in the frame. Once I replaced the ignition with the GL1000 ignition the motor slipped right on.
Now it’s easier to just started redoing parts and getting them mounted.
This is the GL1100 motor in the GL1000 frame. It has the 1977 GL1000 cams, rockers and ignition.
Here’s what the GL1100 motor looks like in the frame. Once I replaced the ignition with the GL1000 ignition the motor slipped right on.
Now it’s easier to just started redoing parts and getting them mounted.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
Been awhile since I updated this thread. We’ve had summer-like weather here until the last couple days and that has slowed progress on GM3.
I have gotten work done on the radiator, shelter, rear brakes, etc. Mostly, I got the the wiring sorted out to integrate the GSXR handlebar switches into the GL wiring harness and electric fuel pump.
I have gotten work done on the radiator, shelter, rear brakes, etc. Mostly, I got the the wiring sorted out to integrate the GSXR handlebar switches into the GL wiring harness and electric fuel pump.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
Seat and body panels are only on to figure out what to do with the rear fender, taillight, seat, etc. Not 100% sure which direction I’m going for a final product. Originally was thinking cafe, then a mild touring bike and now I’m not sure again.
Having the body panels on did allow me to mark the lower triple trees for the steering stops. Also, I got a steering damper with the GSXR front end so I’m looking for a way to mount that.
Now that it’s cold out I’ll have more time to spend on this bike.
Having the body panels on did allow me to mark the lower triple trees for the steering stops. Also, I got a steering damper with the GSXR front end so I’m looking for a way to mount that.
Now that it’s cold out I’ll have more time to spend on this bike.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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- True Blue Steel Biker
- Posts: 2314
- Joined: Wed Apr 11, 2012 10:50 am
Re: Gold Member
Beautiful legs.
Dave
1975 GL 1000
1980 XS650
1981 ct110
1972 F7 KAW 175
2000 moby blaze 40cc
Chihuahua (Ellie)
Chihuahua #2(Blaze)
1975 GL 1000
1980 XS650
1981 ct110
1972 F7 KAW 175
2000 moby blaze 40cc
Chihuahua (Ellie)
Chihuahua #2(Blaze)
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
Why thank you
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
I got a 1978 parts bike that had been sitting outside for at least a decade. Pretty rough. Had to unload it with a forklift because both wheels are locked up. I wouldn’t have bothered with it except it has a 4 into 1 exhaust that I’m going to try to fit to GM 3.
Looks like the pipe is stainless steel which explains why it didn’t rot out.
Stripping anything I though I could use, and there isn’t too much, I found that the motor and carbs are actually 1977. So I’ll pull the cams and rockers. That was a nice surprise.
Looks like the pipe is stainless steel which explains why it didn’t rot out.
Stripping anything I though I could use, and there isn’t too much, I found that the motor and carbs are actually 1977. So I’ll pull the cams and rockers. That was a nice surprise.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
Got the parts bike torn down as far as I’m going to. Carbs are good, cams not so much. Still got lots of rubber bits, electrical harness, switches, etc.
Time to send the rest down the road.
Also got a pic of the steering stabilizer mount on GM 3.
Not sure what the 3 threaded lugs on the headstock of the frame were used for, but they made a good place to mount the stabilizer.
Time to send the rest down the road.
Also got a pic of the steering stabilizer mount on GM 3.
Not sure what the 3 threaded lugs on the headstock of the frame were used for, but they made a good place to mount the stabilizer.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
Got a soda blaster set up and an old school zinc plater to help with the carb rebuild. the Randakk’s carb kits are very nice too.
Had a little trouble with one of the float needles, but got that sorted out and the carbs are leak tight with the K&N electric fuel pump.
Electronic ignition set and a start up. Runs good. A bit of smoke on deceleration, but I think that will work itself out.
Recap: 1977 GL1000 frame and body, 1981 GL1100 motor with 1977 cams and ignition, 1976 carbs, 4 into 1 exhaust, 2002 GSX-R1000 front end and brakes.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
- Fred Camper
- Vice President
- Posts: 6918
- Joined: Wed Aug 12, 2009 9:38 pm
- My Album: http://www.ngwclub.com/gallery/v/wingmans/Jeff+Bozeman/
- Location: Metro Detroit
- Contact:
Re: Gold Member
Wow, you are getting very close to completion. Great progress on the front end. Love it.
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
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
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
TY!
Still lots to do.
Make front disc carriers for the 320mm rotors, upholster the seat, build mounts for front fender, mount headlight and speedo, etc.
Been a bunch of fun so far.
This week will be refinishing the rear wheel and lacing with new spokes.
Still lots to do.
Make front disc carriers for the 320mm rotors, upholster the seat, build mounts for front fender, mount headlight and speedo, etc.
Been a bunch of fun so far.
This week will be refinishing the rear wheel and lacing with new spokes.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
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- Chrome Member
- Posts: 146
- Joined: Sat Jan 02, 2010 6:55 pm
- Location: The Flatlands of NW Ohio
Re: Gold Member
Preparing the rear wheel from the parts bike for new spokes.
The bearing retainer was completely stuck. Drilled out the stakes, but no amount of penetrating oil or heat would let it budge.
Ended up welding out the aluminum retainer to save the hub.
The bearing retainer was completely stuck. Drilled out the stakes, but no amount of penetrating oil or heat would let it budge.
Ended up welding out the aluminum retainer to save the hub.
2005 Suzuki DL1000
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
1977 GL1000 rider
1977 GL1000 project
1999 WR400 off road
2000 WR400 Supermoto
2003 TTR125 Pit Bike
1984 ATC200M
- Fred Camper
- Vice President
- Posts: 6918
- Joined: Wed Aug 12, 2009 9:38 pm
- My Album: http://www.ngwclub.com/gallery/v/wingmans/Jeff+Bozeman/
- Location: Metro Detroit
- Contact:
Re: Gold Member
They can be a bugger. Slightly oversized drill is okay, but you are correct that they still want to be tight. Glad you got it out.
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
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
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