1978 GL1000 Low Buck Project

[Goboy]

Install belts, insuring the timing marks are lined up when you do. Its easier to work on one belt and tensioner pulley at a time, less chance of messing up the timing. Leave the tensioner pulley bolt a little loose and manually turn the engine "several rotations" and then tighten the tensioner pulley bolts. The belt tension should now be fairly tight.

Tensioner pulleys and hose.jpg

I had my rad off so I installed a temporary hose so I could run the bike. You have to readjust the tensioner pulley tension with the engine at operating temp. Watch the temp gauge and feel the hose as you bring the engine to operating temp.
Check the belt tension now, then loosen the tensioner pulley bolts and turn the engine and re-tighten the bolts. Never force or push the belts, let the springs do the tensioning. This may be a good reason to change your springs once in a while.

[Goboy]

Now after re-checking the timing marks you can install the rad. but I have a new problem. When I had the engine warming up I noticed that the right cam sprocket was wobbling. A PO had dropped the bike as the right crash bar was ground flat on the bottom. Something must be bent, removed the sprocket,checked, reinstalled, same. The rear cover plate was also bent and had cracks.

Rt pulley cracks.jpg

So picked up some used parts. Cleaned painted the rear cover plate, installed the new sprocket and belt, manually turned the engine and tightened the tensioner pulley bolts, checked the timing marks. All Ok, cranked it over, no wobble!!

Rt rear cover old-new.jpg

[Goboy]

Easy fix for rotted rubber bushing (or washers?) for electric radiator fan mount, use pieces of vacuum hose.

Homemade rubber bushings.jpg

[Patriccio]

That's it! Nothin' fer a year?! I think you might be in violation of some by-law in another galaxy. Nice little triptych thing w/ the pics.

[Goboy]

I'm definitely in violation (I maybe banished from this site if I don't pull up my socks ). I've done a little and adding pic's SLOWLY!! I'm going to rename it the Slow buck project! I just have too many things on my too do list.

[heraldhamster]

...I just have too many things on my too do list.

we should start a club. I haven't built one in over 4 or 5 years (and I have 3 waiting to get built)... but I have a runner, almost two (but no time to track the problem on the 2nd).

likin' your progress. especially those replacement bushings. good on ya, man.

[ericheath]

Duke182, that was your queue.

[Goboy]

Since Patricco been prodding me for something, anything, I submit "THE PAINTING OF THE RADIATOR". It took 3 long nights to sand all the nooks and crannies, wiped it down twice with wax and grease remover. Then sprayed it with black caliper paint and baked it for 30 min. @ 250 (or until lightly browned). Then threw in a frozen pizza to get rid of the smell. I still can't believe the wife didn't put up a fuss.

Rad sanded.jpg

Rad painted.jpg

[Patriccio]

That turned out quite nicely. I suggest Radiator of the Month.