78 GL1000 - Brat-Style/Tracker Project - First Build

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Cjohnson
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78 GL1000 - Brat-Style/Tracker Project - First Build

#1

Post by Cjohnson »

Hi everyone, I've posted a few times here asking random questions and figured I was a little overdue to start a project thread. I picked up a 78' last November and got it completely disassembled. I was planning a pretty ambitious rebuild over the course of this year but now it is looking like I'm moving to Houston this summer, so I'm scaling back a bit on my plans have it at least mostly put together prior the move.

So far I have the frame powdercoated and the engine/radiator painted. I was planning on doing a front end swap with some really beautiful black/copper-ish gold GSXR1000 forks that I picked up cheap from FB marketplace, but that is going to have to wait now. Getting ready to re-assemble the stock front end with a Biltwell Tracker handlebar.
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#2

Post by Cjohnson »

As purchased:
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Cjohnson
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#3

Post by Cjohnson »

Current State:
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#4

Post by Fred Camper »

Looks like a great starting point. Frame and engine look great. Agree that the GSXR fork can wait for phase 2. Be careful with the wiring as the GL1000 harness is pretty darn complicated. There are wiring diagrams in the shop talk section that may be your friend. Many of us have shortened the bars, the clutch cable can either be shortened (see shop talk post by Hott) or you can get more creative with a longer route back to the rear of the engine.
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#5

Post by Cjohnson »

Now:
I'm a ways off from wiring, but my plans are to do a m.unit blue (once they are available again), lithium battery conversion. I've put together a draft diagram of my wiring plans, would love to get input/corrections here.

A few questions I do have
1. The connection between the points, coils, and condenser. Should there be a diode or something at that connection? If so, can anyone post a picture of what that component looks like?

2. I am omitting the temp and voltage gauge (switching to a 77' faux tank) and dropping in an aftermarket fuel level gauge. If the gauge is 12V (10-73ohm) and I omit the 7V regulator. The OEM sending unit should operate just fine, correct? as the gauge is only reading resistance is shouldn't matter what voltage the sending unit sees?

Thanks in advance!
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#6

Post by Cjohnson »

Fred Camper wrote: Fri Mar 03, 2023 1:25 pm Many of us have shortened the bars, the clutch cable can either be shortened (see shop talk post by Hott) or you can get more creative with a longer route back to the rear of the engine.
Thanks Fred, I was concerned about replacing/shortening the cables for the lower handlebars now only to have to revisit the cables when I do the front end swap. The new top tree will be lower profile than stock top tree, not sure if the additional .5-1" drop is enough to require all the cables to be re-shortened.

The choke lever will re-located under the faux tank, possibly the ignition switch too.
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#7

Post by pidjones »

When building The Hunley, I went to low, "Euro bars". Throttle cable excess was not really a problem, but I found that running the clutch cable over the top, right side of the air cleaner cover took up just enough to make the installation nice looking and smooth operating. The cable had to be routed over the top of the speedo, also. This was due to both bar and perch geometry.
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#8

Post by Cjohnson »

Thanks for the advice on the clutch cable, I’ll probably go that route in the interim and shorten it properly once I do the fork swap.

I am planning to use the stock headlight/turn signal brackets but want to use some much lower profile turn signals, but turn signal mounts are completely stuck in their respective headlight brackets? Any thoughts on how to remove them?

New steering bearings will be in later this week so front end reassembly can begin.
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#9

Post by Cjohnson »

IMG_0977.jpeg
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A couple quick questions here:

Why is there such a big gap between the top of the headlight bracket/fork covers and the top triple tree? I replaced both of the steering stem bearings, does this indicate an issue?

2nd question, wiring for the new turn signals, is it exiting the headlight brackets/fork covers in the right way?

3rd question, any tips/tricks on getting the forks pushed all the way in to the triple trees? One went in all the way no problem, the 2nd slid through the lower tree but I can only get it part way into the top tree. The rubber fork covers installed below make it difficult to grip the top of the fork, as you can guess grabbing the bottom of the for results in me just compressing the fork.

Thanks in advance for the input
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#10

Post by pidjones »

1- get a parts list and see what you are missing 2-hard to tell from the photo, but if it isn't pinching through insulation it should work 3-CAREFULLY spread the clamps to allow the legs to go up fully - actually they should be able to go through too far.
"Love 'em all.... let God sort 'em out!"
Ex 2006 GL1800 - the Black Pearl SOLD! to make room for:
2021 Can-Am Spyder RT Limited Dark Chalk Metallic
1975 Red GL1000 project - ex Pistol Pete project
1972 Triumph T150V Trident rescue - finished and FOR SALE!
1976 Yamaha RD400c
1978 GL1000 with '75 engine - the Hunley
Ex 1978 GL1000
Ex 1979 GL1000
Ex '79 CB750F rat bike
Ex '86 SEi
Ex '77 GL1000
Ex '76 RD400
Ex '72 Penton 125 set up for flat track
Ex '73 RD250
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#11

Post by rcmatt007 »

pidjones wrote: Sat Mar 04, 2023 10:22 am When building The Hunley, I went to low, "Euro bars". Throttle cable excess was not really a problem, but I found that running the clutch cable over the top, right side of the air cleaner cover took up just enough to make the installation nice looking and smooth operating. The cable had to be routed over the top of the speedo, also. This was due to both bar and perch geometry.
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#12

Post by Cjohnson »

Figured out I’m missing the “Rubber fork covers, upper” not sure where they wandered off to. Anyone know where I could source these in the US? I found one person offering them for a ridiculous price on eBay. Honda PN 51601-371-000.
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#13

Post by RazMan »

Looks like I am embarking on a similar project - mine is a 1984 GL1200 but there are obvious design similarities.
Your M Unit diagram looks really good and this is my 6th Motogadget build - they are a real gamechanger!

A couple of comments:
  • I am not sure why you have a resistor feeding the coils and not neccessary imo

    I can confirm that the standard oem fuel sensor works fine with aftermarket gauges.
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#14

Post by RazMan »

Cjohnson wrote: Fri Mar 03, 2023 1:10 pm Current State:
Looks really nice (although a bit upside down lol)
Can I ask how you painted the engine?
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Re: 78 GL1000 - Brat-Style/Tracker Project - First Build

#15

Post by Cjohnson »

RazMan wrote: Thu Jun 29, 2023 4:15 am
Cjohnson wrote: Fri Mar 03, 2023 1:10 pm Current State:
Looks really nice (although a bit upside down lol)
Can I ask how you painted the engine?
Eastman high temp ceramic paint and a hvlp spray gun. 90% of the battle was getting the engine clean enough.
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