My 77 Cafe idf build

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Olyclo
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My 77 Cafe idf build

#1

Post by Olyclo »

Thought I’d share my build!

Bought as a barn find in a bad way. It’s a 77 and I’m the second owner! Only 18 thousand miles on her.

Completely stripped and rebuilt.
Frame powder coated & internally rust proofed.
New bearings all round.
Respoked wheels.
New head gaskets & belts ( belt had been broken so had to renew an intake valve )
Calipers rebuilt with braided lines.
New rear shocks.
Triumph seat.
Clip ons.
1100 side panels ( preferred the look )
Webber idf conversation using Randak manifolds.
New universal exhausts.
Repainted 75 gl blue/green
Etc etc

3 years of tinkering, I now need to get it running right! Idles perfect but runs very rough so need to go through carb settings.

Hope the pictures uploaded. Still got 3 years of dust on it as that was its first test run out!
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77 Gl1000
MattMcCoy
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Re: My 77 Cafe idf build

#2

Post by MattMcCoy »

Looks awesome—congratulations!
1983 GL1100A Aspencade
1977 GL1000
1978 GL1000
1979 GL1000

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Jonesz
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Re: My 77 Cafe idf build

#3

Post by Jonesz »

Very nice work! Like the look and color. What mufflers did you use?
Jonesz

1983 GL1100 Aspencade named "Freki" currently undergoing change to a standard. 95% Done
1999 Valkyrie CT 1500 goes by the moniker "Valerie"
1978 Gl1000 "Loki" new project going to be a Cafe Convertible
1979 Suzuki GS850
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Chainman
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Re: My 77 Cafe idf build

#4

Post by Chainman »

Beautiful. She's a real gem action1
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BruteSquad
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Re: My 77 Cafe idf build

#5

Post by BruteSquad »

Nice looking bike! well done.

How do you internally rust proof the frame?
1977 GL1000
2006 DL650 VStrom

“Always do what you are afraid to do.” - Ralph Waldo Emerson
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gregforesi
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Re: My 77 Cafe idf build

#6

Post by gregforesi »

Nice. I've always had a soft spot for cafe bikes (and no Rat, it ain't on the top of my head!).
If you'll post your jets and settings maybe I can be of some assistance. BTW do you have a copy of Randakk's instructions? There was a poster here in need and mine are gone.
Last edited by gregforesi on Wed Jul 07, 2021 3:31 pm, edited 1 time in total.
2006 GL1800 (Brutus Maximus)
1978 GL1000 (White Trash - 2012 BOTY
(If you want to discuss the Trashmobile, Webers, Rearsets, Clubmans, or other stuff then send me a PM.)
"Getting old ain't for sissies" - Phyllis Diller
"So how much you gonna spend to win that $5 trophy?" - Cyborg
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5speed
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Re: My 77 Cafe idf build

#7

Post by 5speed »

very nice build
1982 1100 standard.
1976 GoldWing. running but not on the road
1978 Goldwing. future cafe project.
1986 Yamaha FJ1200
2019 Can-Am ryker (boss's new ride)
2002 Shadow American Classic(sold)
1983 Shadow 500. (sold)
Kingpin06
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Re: My 77 Cafe idf build

#8

Post by Kingpin06 »

Love the color. Cafe bikes are awesome.
Olyclo
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Re: My 77 Cafe idf build

#9

Post by Olyclo »

BruteSquad wrote: Wed Jul 07, 2021 11:18 am Nice looking bike! well done.

How do you internally rust proof the frame?
I used Bilthamber. You can get it with a nozzle hose. Found a hole in the frame, injected it and let in run all through it and drain out.
77 Gl1000
Olyclo
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Re: My 77 Cafe idf build

#10

Post by Olyclo »

gregforesi wrote: Wed Jul 07, 2021 3:24 pm Nice. I've always had a soft spot for cafe bikes (and no Rat, it ain't on the top of my head!).
If you'll post your jets and settings maybe I can be of some assistance. BTW do you have a copy of Randakk's instructions? There was a poster here in need and mine are gone.
Hi Greg, you actually helped me a lot during this build with different problems I had ( coils etc ) so for that I truly thank you!
I do have Randakks instructions here. And am more than willing to help in any way I can. Although I understand these were not to be shared as it’s part of the value added etc but if u can advise on that I’m willing to help!

I jetted according to the instructions, I set the ignition timing the other night and believe the carbs to be well synced as I have a carb syncrometer. The bike now idles perfectly at around 1000rpm and starts easily. It is however nearly unrideable as it pops and backfires until about 5000rpm and then it clears and pulls hard ( if I use full throttle ) it’s so bad I think maybe a vacuum leak. The carbs were cleaned with new ( as instructed ) sized jets fitted.
Any suggestions would be so appreciated!

Thanks again
Oliver
77 Gl1000
Olyclo
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Re: My 77 Cafe idf build

#11

Post by Olyclo »

Jonesz wrote: Tue Jul 06, 2021 6:49 pm Very nice work! Like the look and color. What mufflers did you use?
They are just universal eBay jobs. Sound really well and have removable baffles. I’ll try and find the link for them.
77 Gl1000
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gregforesi
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Re: My 77 Cafe idf build

#12

Post by gregforesi »

"It is however nearly unrideable as it pops and backfires until about 5000rpm and then it clears and pulls hard ( if I use full throttle )"

There is no mid-range circuit so the idle circuit must be rich enough to transition to the mains. The accelerator pump is a big part of that transition too. I have a pretty easy flowing system with the velocity stacks and (now) Delkevic exhaust. My settings are: 50 idle jets, 110 mains, 135 air correctors, 9mm of thread showing on the accel pump adjusters.
Your low speed mixture screws should be between 3/4 and 1 turn off the seats. You will get that with either a 47 or 50 idle jet.
The bike should idle with the butterflys open by just 1/4 turn on the idle adjusters. Any more than that and the progression holes start to get uncovered and can give you a false impression.
If the bike is falling on it's nose at 3000 - 3500 or something like that it's the accelerator pump. Crank it down to show more thread (less squirt).
My #1 problem was with Randakk's suggestion for the air correctors. You can see that I ended up a lot smaller than his. That was the result of a dyno run. The accelerator pump adjustment was trial and error.

So when I first started out I was getting way too much squirt from Accel pumps and it bogged. Then as it got to the top end it was getting way too much air through the air correctors and it was running really lean. Instead of buying a bunch of air corrector jets I invested in micro drills. The brass solders closed nicely and then I just drilled them to size.
2006 GL1800 (Brutus Maximus)
1978 GL1000 (White Trash - 2012 BOTY
(If you want to discuss the Trashmobile, Webers, Rearsets, Clubmans, or other stuff then send me a PM.)
"Getting old ain't for sissies" - Phyllis Diller
"So how much you gonna spend to win that $5 trophy?" - Cyborg
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desertrefugee
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Re: My 77 Cafe idf build

#13

Post by desertrefugee »

gregforesi wrote: Sun Jul 11, 2021 10:06 am "It is however nearly unrideable as it pops and backfires until about 5000rpm and then it clears and pulls hard ( if I use full throttle )"

There is no mid-range circuit so the idle circuit must be rich enough to transition to the mains. The accelerator pump is a big part of that transition too. I have a pretty easy flowing system with the velocity stacks and (now) Delkevic exhaust. My settings are: 50 idle jets, 110 mains, 135 air correctors, 9mm of thread showing on the accel pump adjusters.
Your low speed mixture screws should be between 3/4 and 1 turn off the seats. You will get that with either a 47 or 50 idle jet.
The bike should idle with the butterflys open by just 1/4 turn on the idle adjusters. Any more than that and the progression holes start to get uncovered and can give you a false impression.
If the bike is falling on it's nose at 3000 - 3500 or something like that it's the accelerator pump. Crank it down to show more thread (less squirt).
My #1 problem was with Randakk's suggestion for the air correctors. You can see that I ended up a lot smaller than his. That was the result of a dyno run. The accelerator pump adjustment was trial and error.

So when I first started out I was getting way too much squirt from Accel pumps and it bogged. Then as it got to the top end it was getting way too much air through the air correctors and it was running really lean. Instead of buying a bunch of air corrector jets I invested in micro drills. The brass solders closed nicely and then I just drilled them to size.
Dang Greg. This post is golden - and if I'd seen it a couple of years ago when I went through my Weber phase, I might have left them on. I was experiencing similar issues, but mine was mostly an off-idle bog. I didn't do the A/F verification thing and always suspected an overly lean condition. Dinked with the accel pumps incessantly and dang near went broke ordering slow jets. (Wasn't smart enough to go the micro-drill route, I guess). In the end, I wimped out and went back to the OEM rack.
Webers.jpeg
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gregforesi
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Re: My 77 Cafe idf build

#14

Post by gregforesi »

The OEM's are fine. They just don't run as well. Here is the bike rigged as a B-17. (Cyborg is probably still jealous).

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2006 GL1800 (Brutus Maximus)
1978 GL1000 (White Trash - 2012 BOTY
(If you want to discuss the Trashmobile, Webers, Rearsets, Clubmans, or other stuff then send me a PM.)
"Getting old ain't for sissies" - Phyllis Diller
"So how much you gonna spend to win that $5 trophy?" - Cyborg
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CYBORG
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Re: My 77 Cafe idf build

#15

Post by CYBORG »

Jealous????? Never! If I wanted one like that, I would just build one. :lol: :lol: :lol: :lol: :lol: :lol: But I do like it. :lol: :lol: :lol: Never been a fan of that carb arraignment. But all in all, a great bike, and a greast build
1978 custom GL1000
1977 custom with 1200 engine
1985 gl1200
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