Pauls GL 1000 Project

[Roady]

Welcome back Paul. Seems it's always something.

Have you checked that the fan is working when you hotwire it to the battery? Had trouble with mine running intermittently and it ended up being cruddy inside the fan. Opened it and shined things up and it works perfect now.

[Cookie]

On those fuel tank drains I use liquid teflon or Permatex.

[rogue1000]

I've just read thru to this point..great project! It seems as though you are almost there; persistence, persistence, persistence! Nothing else seems to get you there.
The bike sounded great without the mufflers, though I don't think the neighbors would approve for very long; still, a very throaty sound. You should have someone take a video of you riding when you get the brakes done..that would be cool! Cheers ,BC

[paultjack]

Brakes are now on, Master cylinders rebuilt. I just need to attach the front brake lines and then add some fluid and start bleeding.

Went to the Vintage Japanese Swap Meet yesterday and met up with Neil. I rode my Rebel 450 and he brought his GW. Neil's bike is very cool and I hope you get a chance to see the work he's done to it.

I found some side-cover bolts - the ones with the springs that hold the covers to the frame. I think they're for a different year and I'm not sure if they'll work. I originally only had one so the two new ones will be a great help if they fit. I glanced at my old one and I think it's shorter and perhaps skinnier. Well, I guess if they don't fit it just gives me another excuse to modify something!

I also found some new hand grips. Nothing fancy. Just something to allow me to get to the next phase of customization while allowing me to remove the Gay (not that there's anything wrong with it) "Live to Ride Ride to Live" grips that were stuck on there.

Neil reminded me of the deadline to reserve a room for Ranndakk's rally in September. Anyway, the goal NOW is to pound on this thing, get it on the road today and then get the license plate tomorrow for some real road testing!

Once I get this sucker tagged and on the road I'm going to call this restoration project complete. Then I plan on starting a Customizing thread! After all, I haven't really customized anything yet! It's just been mostly just getting it back together and in working condition. I still have my "Robert's Streetfighter" vision in mind. I've go the new mufflers that have to be fitted to the headers, the new handle bars to pick out, new headlight, turn signals, seat... just to name a couple of the items that will go into the customization thread in addition to all the paint touch-up I have to perform! That leaking gas tank drain did a number on the swing arm and the engine install with my buffoon friends will require a little engine and frame touch-up. Plus anything I'm not admitting that I caused to be screwed up!

Anyway, the light at the end of the tunnel is no longer just a light but more of an exit at this point! It's a large hole I'm about to drive this wing right on through!

[Neil]

Good deal, glad you found some items that hopefully will be of use, I'm still thinking about those Yamaha 650's, wouldn't mind bobbing one of those.
Hey, good luck on getting the old girl out and on the road ... looking forward to the ride to Randakks Rally 8)

[paultjack]

OK, brakes are still a problem. Looks like I'm tearing those apart again. There's something wrong with the o-ring that joins the two rear caliper halves. It appears to be just a fraction too thin. The result is brake fluid everywhere.

Font master cylinder piston is binding. I'll have to check to see if I put the front piston cup in backwards. I don't think that's it but who knows...

To get my CB450 Headlight bucket in I had to "modify" it a tad bit. Seems that it was binding on the back of the clocks and ignition switch. It stuck out too far and wouldn't allow me to bolt it on. So, with the help of my trusty torch I heated that sucker and pressed it against the carport floor. Fits now! Also, it received a new coat of black enamel paint to hide the scorch marks. Looks good - no complaints from me!

Now, for the good news! I have successfully ridden around my yard twice! Clutch needs adjusted, really got to get that neutral light working - I tested the switch and that's fine. Plus, I have to figure out why the radiator fan isn't kicking on now.

Burned my leg (just lightly) on the right muffler. That'll teach me to ride wearing shorts!

Looks like tomorrow I'll be stopping by the MVA for a tag! If things go well with the dumb brakes looks like I'll have this buttoned up by the end of the week!

[Neil]

Sounds good Paul. Wish I was there to help. Luck

[paultjack]

I now have a License Plate! I spent 45 minutes in the "Information" line just to get my number and paperwork. I sat down and before I even had the opportunity to open my pen they were calling my name! I told the lady behind the counter I hadn't even started! She said not to worry, just sign this paper and everything will be taken care of! Now that's service! I basically bypassed 50 people ahead of me!

So, got home and pulled the fan switch. The switch is perfect... The sensor was crapped out. So, I pulled out my secondary switch and threw it in a pot of boiling water. After heating and cooling several times I confirmed it was working perfectly! So, I put everything back together. Damn thing isn't working now!

I did put in a new thermostat while I was there. Thanks to the Cross-Over parts list in the Shop-Talk section and Roady for his post about the NAPA #101 I had a new thermostat for something like $7

Additional, a big thanks goes to Roady once again for his Geo Metro Fan Switch replacement! Price with shipping came to under $13.

Check to the Shop Talk if you have a question! That section really is a life-saver and a time saver!

Anyway, had boiling water coming out the cap so I know it was hot enough to cause the switch to activate. Now I have to take it all apart again when the new switch comes in!

Also, now my headlight isn't working. WTF! worked yesterday. Well, it worked before I washed down the bike. Looks like I'm tracing wiring again! But! I DO have a license Plate so life is good!!!

[rogue1000]

Way to go; a ride after all that work must be bliss! I'm envious...........

[paultjack]

Thanks Brian!
It was quite exciting to tool around the yard a couple of times! Most of the excitement was wondering if something would fly off or if I'd be able to stop!

I did try working on the brakes when I got home and had the same result of the front master cylinder piston seeming to be sticking. So, I finally broke down and tore it apart once again. And good thing. Seems the piston cups were in fact installed correctly - they were not the issue. The issue was with the metal barrel that pushes them. After taking it out it showed score marks. I mic'ed it out and it appeared to be about .001 larger in diameter than the original I replaced. So, I hit it with some 1000 grit wet/dry sand paper and lightly honed the cylinder while I was at it. Smooth as silk now! Had the front brakes bled out in about 10 minutes!

Additional notes:
While at NAPA I discussed with the counter boy - how young can you be to work at a parts store? - about re-working my tad-to-long front brake lines. Basically I have three options - make new lines, cut one end and attach a new fitting or cut a piece out of the middle and throw in a connector. I think I'll just have a new end put on if he has one that'll work. If not, I'll just put in the splice. The good thing is counter boy is only going to charge for the connector/fitting - no "crimping fee". So, basically I'll get my brake lines corrected for a few dollars. Should have just gone there first and had custom lines made. Would have been cheaper in the first place.

Now, gotta get that headlight working and figure out what to do with the rear brakes! Too dark out now to see anything - blasted end of summer darkness!

[Roady]

Oh Man! This one is getting real close to done.

I'd wondered about having lines made at NAPA. The store by me has a sign in the window ... so they must have the banjo fittings, right?

Would be cool to have a front set made that eliminates the junction, just two lines from the MC to the calipers.

[paultjack]

Where are my cables??? I still haven't found my choke or speedometer cables! Those things have to be here somewhere!

OK, tracked down the headlight... It's the starter button. Push it up and the headlight turns on... I'll have to brake that down and give it a good cleaning! Anyway, glad it wasn't anything critical.

Took the bike out on the street for a test ride. Ran it up and down through the gears and didn't see any problems. Really happy about that! This thing rides and handles like a dream. It's like night and day compared to the Rebel.

Determined I need to adjust the clutch a bit. So, it's down to the rear brake problem and then I'll be ready for a good road trip test. Like Roady said, this is getting real close to done!

[starket]

You are so close. I know how I felt when I got that close on my 75 project. I also understand the wondering on the first ride. A freshly restored bike is such a dream to ride. Git-R-Done and enjoy. Since you are on the east coast, are you going to take her to Randakk's Rally

[Cookie]

On those handlebar switches sometimes a couple blasts of Radio shack contact cleaner prevents dissasembly. If you figure they aren't really sealed that is just good maintenance.

[paultjack]

At this point I'm planning on attending Randakk's Rally. I have my room booked and my $22 in to Randakk. So, as long as nothing happens I'll be there! However, I have as my backup plan to take the Rebel down. I might strap the tank and side covers from the wing to the rebel! It'll be a GL450 LOL