NGWClub®, Inc.

I started working on this project a while back, but haven't posted a thread until now...better late than never, so here it is...

A couple of years ago, I found this poor girl sitting all alone in the snow desperately needing someone to bring her back to life. She hadn’t be running in more than twenty-six long years (with gas in the tank and carbs to boot).

I started out that day to buy a neglected Honda CB900 and the owner also had the GL1000 sitting outside and asked if I was interested in buying it. Initially I just gave her a quick glance and declined as my sights were set on the CB. (also, it was several degrees below zero at the time and I didn't care to dawdle outside for too long)

Later, after buying the CB I gave the GL more consideration and ended up going back to buy it as well. After all, I had room in my trailer and at first glance it looked like it was all there and surely it would not be too hard or too expensive to get her up and running again…right?

Well, we all know what that kind of thinking can lead to…$$$$

Closer examination back in the garage, revealed she might need a bit more work than I first thought in order to get her going again...

One of the first things I had to do was drain that 28 year old stale gas from the tank as it was stinking up my garage...I washed out the tank with soap and water afterwards and dried it with a hair dryer...(it still smelled really bad, so I sealed it back up for thorough cleaning later).

After studying it for sometime, I decided she would need a proper total restoration...
Then it was time to spin some wrenches and start disassembly...trying to organize things by putting them in boxes to achieve some sort of order when I went back to retrieve them and reassemble the machine.

I wanted this project done right, so it was off to the blasters with the frame and other large parts....

Meanwhile, back at the ranch, I took on prepping and painting the motor myself...






Plenty of sanding and primer followed by three coats of color and three coats of clear. I was happy with the result.

Wow, engine looks great!

Thanks Handsomesteve...
The motor had some bad gas staining and a general 30 year crud look to it...I used Duplicolor's engine paint, primer and clear and so far am really happy with it.

Keeping the engine on the dolly for painting worked very well. When it came time for the bottom, I simply tilted it over with the valve covers resting on wood blocks, exposing the crankcase fins.

I used the same paint for the engine hangers, front and rear calipers and final drive pumpkin...

Then it was on to the carburetors.
They had been left with gas in them for at least 26 years and had a thick layer of brown varnish inside...

I completely disassembled each one and ran them through several heated cycles in a sonic cleaner using distilled water and a bit of Yamaha carb dip followed by vigorous brushing with a toothbrush to get them clean...

Polished the carb tops and made good use of all the collective knowledge on this site including Octane's write up to dive into the rebuild...using Randakk's excellent carb kit.

I was surprised to find that this required the handling/cleaning or replacement of more than 45 parts PER CARB
(180+ parts total) just for the carbs rebuild...

Then it came time to mate the renewed motor to the frame...

First a new clutch cable and adjustment was in order...

Then lots of blue painter's tape and a little patience was necessary here, but it really wasn't that difficult to do.

Add wheels with new tires and bolt the carb rack onto the motor and it's beginning to resemble a bike again...

A short piece of PVC pipe for the handlebars made it much easier to wheel the bike around the garage...

Your making great progress and fast at this rate you'll be on the road yet this summer, Like what I am seeing, keep up the good work!!!
Hack

I really like the color offset of the valve covers. Excellent job!

Thanks Hack and sgwilly...it's been a bit of a brain teaser and somewhat frustrating at times...especially the carbs...or waiting for that one part that holds up the entire project...

Also the electrical wiring was a problem as previous owner(s) had done their own personal modifications here and there over the years...

I consider it "garage therapy" and it may just keep Alzheimer's at bay at the same time....

Then it was time to tackle the brakes...since I was rebuilding the master cylinders, I painted the calipers and installed stainless front brake lines and Ferodo front pads...much improved!