Brown Dirty-- er Derby

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!

Moderators: Brant, Sagebrush, Forum Moderators

Post Reply
User avatar
Easter
True Blue Steel Biker
True Blue Steel Biker
Posts: 2999
Joined: Thu Sep 13, 2012 11:33 am
Location: South of Houston 100 miles

Brown Dirty-- er Derby

#1

Post by Easter »

I bought this '83 a year or so ago for parts to finish off the red bike I was fighting with at the time. Since I am in need of a project to keep me out of the house I decided that maybe this was worth fixing up after all. It came with a title which is always a good thing and doesn't appear to have any serious defaults other than the missing parts I stole for the last project.

First step was to be sure the engine wasn't locked up. I removed the stator cover plug and was able to turn the engine with a socket, so far so good. After stealing a battery from Dragon Wing and sorting out the wiring a bit the starter was able to spin the engine. Good. Next I pulled the carb wrack and after partial disassembly placed the entire wrack in the ultrasonic cleaner for about a week. (lots of goo but nothing too serious). With the plugs removed the next step was to confirm compression. It has some. About typical for a bike that has been sitting for years, ranging from 125 to 160. A quick look at the belts makes me think they have been replaced recently. The lower radiator hose and inlet thingy were missing so PO must have taken a look at the water pump and decided he was in over his head. Fortunately I have a couple of the thingies and a new hose for top and bottom. But looks like a water pump kit will be a necessity. Before I order that I want to start the engine and see if it will run. The carbs are rebuilt, just waiting on a kit with bowl gaskets and the tiny O rings that go on the pilot screws. (I wish I had a source for these (o ring) since every rebuild needs them and most of the bikes I have worked on use the same size on the pilot screw, often these are the only things that need replacing )

I cheated a bit and cleaned and painted the engine in the frame. As soon as the carbs are back on I will see if I can start it. If it runs I will spring for a water pump kit. If it runs good or can be made to run good, I will move on to the brakes. Front calipers are missing and all components front and back will have to be cleaned and rebuilt. All the plastic is in fair shape and I will wait to see how things go before deciding whether to repaint or just flip as is. The hold up at the moment is the carb bowl gaskets and the pilot screw O rings.
Attachments
20201230_093758_resized.jpg
20201230_093758_resized.jpg (212.18 KiB) Viewed 451 times
20201230_093825_resized.jpg
20201230_093825_resized.jpg (163.54 KiB) Viewed 451 times
20201230_093857_resized.jpg
20201230_093857_resized.jpg (143.23 KiB) Viewed 451 times
20201230_094003_resized.jpg
20201230_094003_resized.jpg (183.79 KiB) Viewed 451 times
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
digger
Billet Alum. Member
Billet Alum. Member
Posts: 207
Joined: Mon Oct 04, 2010 3:42 pm
Location: Ashland Ohio

Re: Brown Dirty-- er Derby

#2

Post by digger »

Easter said, (just waiting on a kit with bowl gaskets and the tiny O rings that go on the pilot screws. (I wish I had a source for these (o ring) since every rebuild needs them and most of the bikes I have worked on use the same size on the pilot screw, often these are the only things that need replacing ).

I get them from here. https://newmotorcycleparts.net/fuel_sys ... rings.html They also have the tiny washers if needed.
1975 GL1000
User avatar
Easter
True Blue Steel Biker
True Blue Steel Biker
Posts: 2999
Joined: Thu Sep 13, 2012 11:33 am
Location: South of Houston 100 miles

Re: Brown Dirty-- er Derby

#3

Post by Easter »

Thanks digger, I can imagine they cost about a penny per dozen to mold but I would be happy to pay the dollar rather than buying a complete kit (of questionable quality) for $22.
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
User avatar
Track T 2411
Honored Life Member
Honored Life Member
Posts: 8482
Joined: Thu May 29, 2008 9:37 pm
My Album: http://www.ngwclub.com/gallery/v/wingmans/Track+T+2411/
Location: Prairie du Sac Wisconsin

Re: Brown Dirty-- er Derby

#4

Post by Track T 2411 »

Just an FYI, Mike Nixon also has those parts, as well as several other hard to find little 'bits' you might need for carbs...
"I have no special talent. I am only passionately curious." - Albert Einstein

"He that is good with a hammer tends to think everything is a nail" - Abraham Maslow

"If you can't take the time to do it right the first time, how are you ever going to find the time to do it over?" -Unknown

Current Rides:
'Grumpy' - '81 Standard, now fully dressed.
'Layla' - '81 Standard w/dealer installed fairing and Hondaline bags.
'Scarlett' '76 'Survivor' nekkid as a j-bird!

Under Construction:
The 'Jalopy' '78-'79 Mash-up
'Quikie' '81 gl1100I back on the lift, project with the step-son!

In The Shed:
'81 gl1100I barn find aka "Josie, the farmer's daughter." (almost comatose build)
'77 gl1000, roller parts bike.
'82 gl1100I, 'Old Crusty' titled roller parts bike (free!)
'82 gl1100I, My first 'Wing, and an expensive lesson!
New2U Bike? Read Me.
User avatar
Easter
True Blue Steel Biker
True Blue Steel Biker
Posts: 2999
Joined: Thu Sep 13, 2012 11:33 am
Location: South of Houston 100 miles

Re: Brown Dirty-- er Derby

#5

Post by Easter »

Thanks Track T, I will check it out.
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
User avatar
Easter
True Blue Steel Biker
True Blue Steel Biker
Posts: 2999
Joined: Thu Sep 13, 2012 11:33 am
Location: South of Houston 100 miles

Re: Brown Dirty-- er Derby

#6

Post by Easter »

Carbs went back on today. Using a veterinarians syringe I primed the carbs with gas. The engine fired up easily and seemed to run fine for the short period I allowed it to run since there was no water and the state of the oil was unknown. I did have oil pressure. I was getting a bit of white smoke out of the exhausts but that is typical of a new start up. Next I drained the "oil". I am not sure what it had in it but it was black and very thin. I am guessing diesel. Again I suspect the PO was trying to flush the engine, possibly it had been locked up, it was a bit stiff when I first tried to turn it over. So now on to water pump and brakes.
Attachments
Started very easily and seemed to run good. Only let it run for a few minutes.
Started very easily and seemed to run good. Only let it run for a few minutes.
20210102_160743_resized.jpg (177.48 KiB) Viewed 370 times
What ever this black stuff is, there is plenty of it.
What ever this black stuff is, there is plenty of it.
20210102_160721_resized.jpg (196.88 KiB) Viewed 370 times
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
julimike54
Zinc Member
Zinc Member
Posts: 51
Joined: Fri Dec 11, 2020 10:44 am
Location: Euless

Re: Brown Dirty-- er Derby

#7

Post by julimike54 »

Oil looks like it might have been overfilled :shock:
1986 GL1200A
Image
User avatar
Rat
Photo Gallery Admin
Photo Gallery Admin
Posts: 15457
Joined: Fri Oct 21, 2005 9:59 pm
My Album: https://www.ngwclub.com/gallery/v/wingmans/rat/
RIP: cookie
Location: Toronto .... Canada

Re: Brown Dirty-- er Derby

#8

Post by Rat »

Good news ... reassuring ...

Gord action1
"I'd rather Ride than Shine"
‘14 KLR650 ... not a rat ... yet
‘84 GL1200i ‘R2B6' (Rat to Be 6, the last, adopted by twowings)
My Original 'RAT' was a hybrid '82 CB900/1100F
User avatar
Jonesz
Silver Member
Silver Member
Posts: 904
Joined: Mon Apr 24, 2017 9:03 pm
Location: Manitoba, Canada

Re: Brown Dirty-- er Derby

#9

Post by Jonesz »

julimike54 wrote: Sun Jan 03, 2021 11:54 am Oil looks like it might have been overfilled :shock:
You might want to reduce the size of the pic on your signature so we don't have to view it full size every post. You will note that everyone else has an avatar if they want to include "their" bike. It may just be me but I find this pic on your signature to be a bit much. Sorry if you take offense, maybe you didn't realize.
Jonesz

1983 GL1100 Aspencade named "Freki" currently undergoing change to a standard. Sold
1999 Valkyrie CT 1500 goes by the moniker "Valerie"
1978 Gl1000 "Loki" new project going to be a Cafe Convertible
1979 Suzuki GS850. Sold
User avatar
CYBORG
Moderator
Moderator
Posts: 24536
Joined: Mon Jan 14, 2008 12:52 pm
Location: Muskegon mich

Re: Brown Dirty-- er Derby

#10

Post by CYBORG »

It is a nice bike ... but the picture is a little large.
1978 custom GL1000
1977 custom with 1200 engine
1985 gl1200
User avatar
Easter
True Blue Steel Biker
True Blue Steel Biker
Posts: 2999
Joined: Thu Sep 13, 2012 11:33 am
Location: South of Houston 100 miles

Re: Brown Dirty-- er Derby

#11

Post by Easter »

In preparation for installing the new water pump which is on order, I pulled the transmission cover and cleaned it for paint. Removing the old gasket is always fun but it really wasn't too bad this time as most of it stuck to the cover and not the block making it much easier to get to. As usual I overlooked a couple of bolts buried in the grease and couldn't figure out why the cover was so stiff coming off. :oops: Since I have been through this several times it didn't take long to realize I needed to look harder for bolts that had been overlooked. There was some build up of gunk on back side of the cover but not more than usual and in fact less than most. I decided to go ahead and check the filter screen while I was at it. Only once before have I attempted this while the engine is in the frame and last time I swore never-again. :IDTS: But time eases all pain. And fools repeat their mistakes. Anyway I learned a really important lesson this time around. Never use a ratchet box end to attempt to extract the front bolt. While you can back it out, it is impossible to remove the wrench and impossible to turn it back in. Wedges and loosening the motor mounts are necessary but still will not give enough room to remove the wrench from the bolt. Solution--saw of the head!

The screen was clean except for what appeared to be black speckles of gasket sealant. Not sure what it was or how it got there but there was not enough of it to indicate a problem and it was easily removed. A lot of trouble but at least now I know there isn't any gravel or broken teeth from gears floating around in the crankcase.
Attachments
20210105_101802_resized.jpg
20210105_101802_resized.jpg (158.97 KiB) Viewed 300 times
20210105_101808_resized.jpg
20210105_101808_resized.jpg (176.5 KiB) Viewed 300 times
20210105_150832_resized.jpg
20210105_150832_resized.jpg (200.57 KiB) Viewed 300 times
20210105_150849_resized.jpg
20210105_150849_resized.jpg (165.28 KiB) Viewed 300 times
20210105_151333_resized.jpg
20210105_151333_resized.jpg (206.97 KiB) Viewed 300 times
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
User avatar
Easter
True Blue Steel Biker
True Blue Steel Biker
Posts: 2999
Joined: Thu Sep 13, 2012 11:33 am
Location: South of Houston 100 miles

Re: Brown Dirty-- er Derby

#12

Post by Easter »

One of the more frustrating things about these old bikes is trying to restore the rear master cylinder. One option is to replace with an MC from a later bike or possibly some other non-OEM source but the ideal situation is to just re-use the original MC housing with new internal components. The big problem with this is getting the old one apart! Air pressure sometimes works but on the 83, the brass insert for the brake fitting means very little air gets back into the MC. My solution in this situation was to drill and tap the piston for a #6 bolt which then was easily withdrawn by prying with a screwdriver. I should note also that the MC had been soaking overnight in mineral spirits to dissolve and loosen the crud that had built up over the years. There is more cleaning to be done but I think I will be able to reuse this Master Cylinder.
Attachments
20210106_182549.jpg
20210106_182549.jpg (159.07 KiB) Viewed 280 times
20210106_182558.jpg
20210106_182558.jpg (108.16 KiB) Viewed 280 times
20210106_182911.jpg
20210106_182911.jpg (115.12 KiB) Viewed 280 times
20210106_182959.jpg
20210106_182959.jpg (159.08 KiB) Viewed 280 times
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
User avatar
robin1731
Membership Admin
Membership Admin
Posts: 21724
Joined: Mon May 29, 2006 8:31 am
Location: Decatur, Indiana

Re: Brown Dirty-- er Derby

#13

Post by robin1731 »

I've mentioned this many times. I drill a small hole and use a sheet metal or drywall screw. Then pry it out.

.
1976 Goldwing Super Sport
1985 Honda Elite
1976 KZ900 Dragbike
1992 ZX7 Dragbike (KZ900 style motor w/NOS)
and a rotation of various purchases
Randakk approved Carb Rebuilder
User avatar
NotSoLilCrippseys
Silver Member
Silver Member
Posts: 522
Joined: Sun Nov 29, 2020 8:21 am
Location: York County, Maine

Re: Brown Dirty-- er Derby

#14

Post by NotSoLilCrippseys »

Jeez.

I'm glad I didn't read this before we started in on our project - and definitely before we jumped in and bought a vintage GoldWing to put back on the road. (It's photos like those that lead people to say, "Don't buy an old motorcycle.")

We have an '83 Interstate project and pulled the rear MC about a month ago. I wouldn't describe the MC breakdown as especially easy given corrosion, but we encountered nothing like what you describe and document. I'll keep these suggestions in the back of my head, just in case our next project isn't like our first!

Our rear MC is cleaned and painted, waiting on my son to spend a little quality time with the rebuild kit.
Avatar is a summer '21 photo of the Blue Phoenix, our 1983 GL1100I rescue gone naked.

In the Stable and Ridable
1992 ST1100 - my longer haul tourer
1992 XJ600S - son's streetfighter
1987 VFR700 - son's latest, in blue/silver
1983 - GL1100I - naked Blue Phoenix (son's, really)
1982 GL1100I - naked bagger Cabernet
1979 GL1000 - Ginger Lynn, but not that Ginger Lynn (Wing and a Prayer)
1978 CB550K - son's cafe (carb issues still vex)

Active Project(s)
1979 GL1000 - Confirmed one owner, with original paperwork. Vetter fairing and bags, off the road in dry, heated storage for 35 years.

Sold
Not lookin' back to avoid regrets
User avatar
Easter
True Blue Steel Biker
True Blue Steel Biker
Posts: 2999
Joined: Thu Sep 13, 2012 11:33 am
Location: South of Houston 100 miles

Re: Brown Dirty-- er Derby

#15

Post by Easter »

Robin, any suggestions for cleaning out and smoothing the cylinder (of the MC) without damaging it?
Bikes at present:

83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process :IDTS:
Post Reply
  • Similar Topics
    Replies
    Views
    Last post

Return to “Members Restorations and Projects”