'82 Cafe Racer Build - GL1100 born naked and will be again

[GW Hobo]

Found some time post holidays and it started with creating a bracket for the LED brake light to fit between the fender and the seat. Rec'd the seat as a Christmas present and Dime City had a cheap LED set up for $36 and this was the last thing I needed to wire: brake light, tail light, and turn signals. I made the bracket out of sheet metal from home depot, but started with a template of paper. Lots of test fits later, I had the finished product, which I bent over my kid's basketball to get a nice round shape. Grinding, primer, and final rattle can paint later, the bracket was ready. The final wiring was a breeze since I'd already tested the brakes and lights/signals on a busted LED signal I had lying around. Then bled the rear brake, slipped on the 'slip ons', removed the center stand (because as my buddy John said, "...it don't make it go faster...") and got ready to take it for a spin...And it died. More on that to follow.

[GW Hobo]

Cutting and finishing the rear brake attachment.

[GW Hobo]

Final finishing.

[GW Hobo]

Final wiring LED brake light, solder/sealed/labeled. Need to add the colors to my final wiring diagram. Still thinking I'm going to wish I wired the gas tank sensor with a small LED near the "dashboard" to show empty, but I'm going to hold off for now until I can find a place for the light where it doesn't look like I forgot to plan for one...which I kinda did.

[GW Hobo]

Final light assembly. LEDs and the m-unit make it easy to change the brake light pattern. I went with the one where when you hit your brakes, it flashes super fast about 5 times, then stays on solid. I think m-unit had four other settings.

[GW Hobo]

So it's not totally done, but it was done enough to ride, given that the only things left to do were send off the tank and panels for paint. So I got my gear on, put on my game face, and let it idle for a bit until all the white smoke cleared. Now mind you, I'd only be idling this bike in neutral for the last few years. Only in January did I put the final drive back on the bike, add grease, drive oil, etc. Before that (meaning never in my ownership and probably not since 2002) had the bike actually been in gear and been driven.

So I got all set, ready to pull out of the driveway, and while I had the front brake on, I pulled the clutch lever and stepped it down into 1st. The bike immediately took off on me and, since I had the brake in, it died. Tried it again with it in neutral, then trying to get into 1st with the clutch in - same result. For the next few times as well. First thought: whatever's wrong was wrong 3 years ago when I bought this bike and I just wasted all this time fixing something that was never gonna run.

I called a couple guys/buddies I know who work on bikes and both pretty much said the same thing: your clutch plates are stuck together. Makes sense given they sat bunched up for 17+ years, no oil getting between them, not moving. One of my guys suggested I just jump on and ride it until they break free. Um...thanks. No. Some research online found this solution: Zip tie the clutch lever engaged and leave it for a several days. At the end of the first day, run the bike engine in neutral and let oil get into the plates. On the 2nd day, with the bike off, sit on the bike and try to roll it forward and backward. Initially it acted like it was in 1st gear = little movement. I tried it some more but same result. On the 3rd day, I rocked it enough that it let me break through and move the bike forward and backward, but it was a struggle. But I walked the bike several feet forward and back again. On the 4th day, I ran the engine, and walked the bike forward and backward to circulate more oil, each time noting that it was easier to push back and forth. That's a good sign, so I broke the zip tie and sure enough, I could tell the plates were free again.

[GW Hobo]

So I'm done for now. To-do includes painting the shelter and side panels and touching up the rims so they look like they match. Probably do both after I've ridden it more - can't stop now. I just put a bunch of miles on it this week, breaking both me and the bike in slowly. It handles great and has a ton of power and kick - makes sense since she dropped a ton of weight. Everything works well. I had a few backfires the first day but that's gone now. I've tried to take it easy and haven't taken it on the highway yet. Lots of looks from neighbors and folks, thumbs up and all. It's good to be finally riding.

After a couple hours on it over the course of this weekend, I parked it. I went over every nut I could access, giving them a little tightening, but found few that needed it. I'll check back in a few weeks again on those. Also, I'll change my oil. It's had very little use, but since the clutch plates were probably gummed up, a buddy suggested I check the oil quality; it looks a little darker.

The stance is fine, but I'd like to see an inch shorter shocks and I may replace the seat and cut out the hump in the frame (near the 'horns'), along with going down a size on the front tire. I don't want to think about what I spent on this $500 engine and frame, but here's a list of work. Some of these upgreades aren't even for Goldwings particularly but are found in the café-racer aisle, and most I did with the help of some great resources on this site and some paid pros who double-checked my work or had the tools and talent to do it right:

- M-unit (no relays, bluetooth now);
- all new wiring, soldered and heat-shrink'd;
- all new lights, extra fog lights, signals;
- new front end, 2001 Yamaha R1;
- rebuilt front and rear calipers and new brake pads;
- cleaned/refurbished carbs;
- new paint on various parts/valve covers/belt covers;
- new seat;
- new custom triple tree and fork conversion kit;
- "new" 1982 gas tank that didn't have 'that much' rust in it;
- new air filter;
- new horn;
- new regulator/rectifier;
- two new solenoids (went overseas-cheap on first one);
- new battery;
- new handlebars, grips, brake and clutch levers;
- hydraulic clutch (thanks Sunnbobb, have not forgotten the swag when I find it - moving again for good in a few months);
- new hand controls wired (drilled) into handlebars;
- new speedo display, custom bracket;
- new rear shocks;
- re-cabled the choke;
- new timing belts (for Whiskerfish);
- new bar-end mirrors;
- custom exhaust, wrapped, with slip-ons;
- license plate holder, and;
- lots of elbow grease (but i'm already hunting for my next build.)

Before and after pics. Thanks for taking the ride with me, for supporting this thread, and for you regulars who support and run this site. I really enjoyed being a new member of the NGW crew. I'll post some pics of the paint job and other touchups; for now this '82 Standard is naked again.

[230Rocket]

Turned out real sharp, I particularly like the rear fender scooping out from under the seat. Love your daughter's flag design, if it were me I'd just get that exactly recreated on the tank shelter, she'll love it and what a talking point.

Cheers
Dean

[sunnbobb]

Man that came out sweet! Good job brother

[HOTT]

That is a good look! Nice job indeed.

HOTT

[Steven UK]

I like it... I like it a lot...!

[wingrider]

Congrats on BOTM! Very nicely done!

[CrazyJerry]

Sharp! Congratulations on Bike of the Month!!
- ~CrazyJerry~

[ericheath]

Cheers, nice work.

[gltriker]