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Hello all.

I recently acquired a 77 GL 1000 with 41k from a friend. He got it running and then lost interest. My plan is to take it down to the frame for a complete rebuild.

I have been lurking around here for a few weeks getting ideas. What a resource!

So far my rebuild list is as follows:
Front brakes, carb, timing belts, front and rear suspension.

Considering that the engine is coming out for a repaint, my question is this: What should I replace/rebuild while the engine is completely accessible? I have no idea of the history of this bike. What is prone to fail that I should sort out now?

I am really not looking forward to dealing with the wiring harness....

Welcome to the site.
If you are pulling the engine I would replace the water pump and the JIS screws that hold the trans cover on with a bolt kit from robin..a site member.
thermostat too.
Also..give the timing belt idler pulleys a good look at to see what shape the bearings are in.
Check the inside of the gas tank to see if it's rusty.
I did the front and back brakes on my 76.
How long has it been since it was running? Might want to consider rebuilding the carbs with 1 of Randakk's kits as well as the petcock in the tank.
That should keep you busy for a while.

Definitely remove and clean the screen by neutral switch while it’s out. It may tell you other things to do. Replacing the neutral switch would be wise as well.

If you’re comfortable with it pull the rear cover and check clutch and stator for wear. Might be worth checking the pins for the overrunning starter clutch to see if they’re getting flat or need a cleaning.

Tell me more about this screen by the neutral switch.

The neutral cover is behind the lower frame making access difficult, then Honda used JIS (Philip’s head) screws making morer difficulter.

Easy when out of frame.

OK. Added to my list of items to take care of!

Well the steering bearings are trash. It is super ratchety to turn. What tool is needed to get the nut off so I can remove the bearings?

They can be done with a good punch or chisel, but making one from an old socket works. I made one a 3/4” pipe coupler for the outer nut. Under the top triple tree it is larger as I recall. Some just use a good set of large channel locks.

why would Honda not just put a "normal" nut on there?!? I'll toss a channel lock on it.

Where in MN are you? I have tools that will take it off without damaging it.

wingrider wrote:Where in MN are you? I have tools that will take it off without damaging it.

I am just outside of Minneapolis, in Plymouth.

If you have a way to bring it up a few miles to my place, I can certainly take it off for you.

I have always found I can get them tore down a heck of a lot faster than back together.

you can find a steering nut tool on ebay. You can also use a punch and hammer but it dings up the nut and you will not know if the torque is right when you put it back on.... somewhere I will have to find a picture of the tool I made to get out the races

Well I took care of those pesky JIS screws on the trans cover. Good thing I read up on the "bingo" method, as it was quite easy with a good whack and an impact driver. I can even imagine trying to get those things out with a frame rail in the way!

I did inspect the water pump, and can see no evidence of impending failure. I am inclined to leave it. replacing it "on the bike" will be much easier now that the Allen head bolts are in.

wingrider wrote:If you have a way to bring it up a few miles to my place, I can certainly take it off for you.

I appreciate the offer! Probably just easier to make the tool, or buy one on eBay...