1978 GL 1000 "The Tank" Resoration Project

[shieldsm]

Alright, finally was able to pick up the bike from my brother's today. Let's just say it did not start out to well...

Blew my truck tire about 60 miles from home. 2hrs of cussing and swearing I changed the tire and then proceeded to open my truck door and low and behold my keys and cell phone are sitting inside with the doors locked. Cussing and swearing x2. Wait an hour until wife arrives. Take inventory of my sanity and proceed.

I bought the bike from my brother who has not touched it in over 4 years in which at that time he bought from a dealer. This is the first time I was able to actually look at the bike. My first impressions were pretty positive (see pic below).

The good:
-Overall good condition. Electrical connections all look sound. No major rust spots anywhere.
-Aftermarket Corbin seat. Bonus #1
-Dynatek III Ignition. Bonus #2

The bad:
-My bro had battery charging problems. Most likely the regulator or rectifier. He bought one of those combo units off a CBR600 but never got around to installing it. The battery is fried as well.

The ugly:
-It is dirty! Looks like some collect of oil surrounding the exhaust manifold but it also could be the lubricating oil that I sprayed on the spark plugs in order to remove them tomorrow.

First thing will be to clean bike as is. #2 will be timing belts. #3 will be Randakk's starting procedures for a long layup. Wish me luck!

The Tank.jpg

Dynatek.jpg

[gregforesi]

If you can - give it a good blow at the quarter car wash before you start into it. "Grunge" directly affects your attitude when disassembling.

[robin1731]

If you can - give it a good blow at the quarter car wash before you start into it. "Grunge" directly affects your attitude when disassembling.

I'll double that. I buy quite a few old barn finds, garage relics. First thing I do after picking them up is hit the car wash. Usually as close to the purchase point as possible. That way it is pretty dry by the time I get home too.

And that does look like a very good starting point.

[rcmatt007]

be REALLY REALLY careful at a car wash.... that hose will put water into places you would think it could never get... I toasted a starter relay once that way

let me add.... the 78's are mighty purdy bikes

[bob]

That is pretty!

[shieldsm]

I took the next 2 days off to dedicate to the bike. My man cave is ready as I have spent some time getting everything set up. I am an anal organize freak type of guy. I plan to wash at home just to be safe. I have a power washer but I may just use some gold old elbow grease to wash her by hand. Also bought the Craftsman bike lift tomake things easier. My lower back cannot handle too much. Spent my allowance for the month.

[heraldhamster]

re: the charging problem... you might want to give a good close look at the "3-wire" connector that comes out of the stator in the rear cover and goes up to the rectifier, I believe... it'll be near the battery vent hose (looking at the battery it is on the left hand side). bad place for it as all those fumes tended to give acceleration to corrosion of the internal prongs inside the connector and once they go there's more resistance, and then there's more corrosion... me? I solder 'em to each other & heat shrink them and completely eliminate the connector. any yellow wire goes to any yellow wire. and the only time you need to undo the connection is if you remove the engine.

[Slabghost]

Nice bike to start with! Congrats!

[shieldsm]

Day 1 accomlishements:

-Wash, wash, wash. It looks much better
-Pulled plugs and shot some lube in there.
-Drained and removed radiator to get at the timing belts
-Proceed to change timing belts. Everything looks pretty good inside. Only got about halfway. Will finish tommorow and check/adjust valves.

Also-thanks for the tip on the charging problems. That will be next after the belts and valves.

I noticed a couple things when removing the timing covers. There seems to be a fine layer of rust powder/dirt on the pullys and such. Not too bad but wondering what I should use to clean this area safely. I was thinking of running some WD40 or type and use a cutetip and get at all the spleens. I just want to have everything looking nice and clean but don't want to blast the wrong stuff. Tensors sound pretty good. Also there seems to be a layer of old sludge at the bottom inner edge inside the timing belt area where it meets the bottom of the timing belt cover/gasket. Not sure if I should be concerned or not at this point. I noticed the timing belt cover bolts were pretty loose so not sure if road grim got in.

[rcmatt007]

I would just squirt green stoff on and hose it off. I would stay away from wd-40 as I would not want it on the belts, and all it really is, is a dust magnet, and dust gathers moisture, and moisture equals rust

[shieldsm]

Rodger,
Thanks for the advice! You saying a degreaser agent like Sumpley Green? It rules how helpful you all are.

I plan to really clean everthing once I can at least feel confident the engine us wortwhule at the initial startup. When I reinstall the radiator just to see her run what is the best method to flush. Would maybe boiling distilled water and running that through be okay until I do a mire through cleaning later?

[rcmatt007]

yes, simply green or whatever it is called... I buy the bulk gallon at Lowes
(not that any of my bikes leak oil)

what you might try with the radiator if it is off, is a vinegar soak which will break up lime. you can also run it with distilled water and radiator cleaner stuff, then cool each time, but flush and run with distilled water several times to flush it out.

Cascade cycle has a new to you kit which also has a new thermostat, and since you are i all that stuff, not a bad time to change that as well

while you are doing the belts, spin the tnsioners to make sure they are smooth and not about to fail

[shieldsm]

Day #2:

Removed the Timing Belts and cleaned inside real good. Proceeded to change timing belts and all seem to be going okay but then the pullys started to move out of alingment while I was struggling to get the belts on. I released all the valve tappets so it made things easier, but I started to get nervous/frusterated as the left pully would pull out of of the pully alignment line. After some struggle I got the belts on and all marks (center, left, right, T-1 were GTG. The only thing of concern was the tensiors seemed pretty tight even as I tried to release the belt with the pully. Its not super tight but the belt is forcing on the tensior quite a bit. The new belt was pretty stiff.

I then proceed the adjust the valve clearances. I triple checked everthing as those damn screws like to turn a bit when tightening the locking nut.

So that is where I am at. I hope the belts are on right. Something please tell me I am worrying about nothing...

P.S. Those damn timing belt gaskets kept coming off as I was putting the covers on. Will be buying new ones thats for sure...

[shieldsm]

I guess what I am concerned about it I had both pully's showing "up" when putting on the belt but does this make Piston #1 at TDC or Piston #2 at TDC (180 degrees out) I get easily confused. Also when setting the valve clearance for #1, should both pulleys be "up".

Like I said, everything lined up and the motor turns just fine. If it was compelting screwed up I assume I would have a really tough time rotating the motor as it would be forcing a valve down into the piston.

[rcmatt007]

I wouldn't loosen the tappets to change the belts. Yes, they will move out of position. See that nut heat in the center, put a socket or wrench on it and hold it in position while you put the belts on.

They BOTH should be UP when the bike is at #1 TDC

the best way is to have started with them both UP and then just let the engine be because it is already in the right position