77 GL Project - Maintenence & Clean Up

[luludog]

Need some help! Been going through the carbs and the jets are all aftermarket and not ID'd. Does anyone know where I can find a jet size chart which tells me the decimal or drill size? Thanks!

[luludog]

Emailed Randakk's about the jet sizing. He responded back very quickly (gotta love that old fashion service!).

Basically, Keihin jets are sized in millimeters.
Here's the example he gave me:

a #35 idle jet is actually 0.35mm
a #120 primary air jet is actually 1.20mm

Found out I had the right size jets

Here's a shot of the completed carbs.


Next, need to finish the coolant parts and assemble the fuel pump.

[luludog]

Rust from the tank did in the fuel pump.

Before


Kept the tach housing and put a new pump on it


Repainted the final drive cover I got from the salvage yard (replaces the chrome one). Finally done with the coolant parts.

[polkadot]

Looks great! Did you make the fuel pump gaskets or buy them? I was going to make some but the parts fische didn't show any, so I put mine back together without them. Seems to be fine. Keep up the great work.

[luludog]

Thanks
The gaskets are new, NOS, still available.

Engine was painted by the PO, not looking very good (runs, not taped well, paint flaking...) I might repaint parts of it if I get more time.

[luludog]

Not much progress, but was able to install the new timing belts. The original ones on the bike were the "Barracuda" brand which some saw as suspect.

[Pokegama]

Really nice work Lulu. The carbs and fuel pump look great!

[ericheath]

Very nice. I am so envious of how the carbs look all shined up.

[luludog]

Thanks guys!

Decided to only clean the engine case and not paint it (will have to wait til next winter or ???)

Finished installing the coolant tubes & ends.


Re-installed the timing belt covers (the rubber gaskets were a bear to hold in place. Ended up using a little adhesive). Also got the radiator back in.


As mentioned previously; the gas tank leaked slightly. Ended up going with Red Kote. First time I've used it. I was afraid the screens would plug up, but they didn't.

[HandsomeSteve]

Really nice work Ray, looks great!

My fuel pump works but now I'm thinking about pulling it off for a look inside.

[luludog]

Thanks Steve.
-----------------------------

Decided to tackle the broken section of tubing on the muffler. That went well, but after removing the chrome brackets; I found two of the studs holding on by a thread. It looks like someone tried to weld the holes around the studs. Kept inspecting the muffler and found more problems. So it was off to the web to see what a replacement muffler would cost. Wow! $150-$500 for used ones. After looking at the alternatives. Decide to get a Motad system (they sure don't give these away). The reviews on-line were great, and the 10 year warranty sealed the deal. David Silver Spares had the best price.

[wingman76]

Ray..thanks for advice on my 76 budget thread, I will do as you suggested on it even if it is a budget build some things can't be ignored while I have the engine out.....you are doing a heck of a good job, what I might try to do next time.
My 77 runs good so if I get the ole Floozy running Im going to have to look at it some. Luckily my 77 I bought it from a guy that had ridden it every year since it was new....but Im sure it could use some attention.

[luludog]

Was able to get back on the GW today. What started as an optimistic day was soon confronted with leaking intake runners. These are the salvage yard specials that I painted. I tested them with a vacuum pump (Randakk method). Two of the four didn't hold. Decided to test the original ones - they were good I had to blast the chrome off and discovered that not only was the chrome flaking off, but the aluminum behind it was pitted.

Here's a pic of one of the better ones after a little sanding.


Two hours of sanding and polishing...


Installed the carburetors & air filter housing


I was on a roll, so in went the tank, shelter frame and misc electrical

[Fred Camper]

You certainly were on a roll, I agree. Looking very cherry. Keep at her, you are getting very close to a ride.

[polkadot]

Looks great! Really, where did you get the other set of runners? Couldn't be the same ones! Nice!