It just looks like trash!
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- Easter
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Re: It just looks like trash!
I managed to get the tank back in without scratching up the new paint! There is no conflict with the master cylinder BUT-- the only place for the master cylinder reservoir is under the seat! I could make it work but I have a decent looking stock MC from the parts bike and maybe it would just be best to stay with that. Ordered the Honda overhaul kit for the MC tonight.
Did run into an unexpected problem with the tank though. My carefully fitted seat/tail piece did not account for the ridge that runs along the top of the tank. I spent a couple hours today trying to make a template that will allow me to make a filler strip to run down each side to fill in the gap. I think maybe it will work. I really like the tail piece and want to use it. Plus I bought a fairly expensive tail light that fits into the back of it and has a license plate holder attached. It was a perfect fit (for once) and I hate to give up on that also.
The big job ahead is sorting out all the wiring for the left and right controls, ignition switch and headlight. A real mixed bag of connectors and wiring colors!!
Did run into an unexpected problem with the tank though. My carefully fitted seat/tail piece did not account for the ridge that runs along the top of the tank. I spent a couple hours today trying to make a template that will allow me to make a filler strip to run down each side to fill in the gap. I think maybe it will work. I really like the tail piece and want to use it. Plus I bought a fairly expensive tail light that fits into the back of it and has a license plate holder attached. It was a perfect fit (for once) and I hate to give up on that also.
The big job ahead is sorting out all the wiring for the left and right controls, ignition switch and headlight. A real mixed bag of connectors and wiring colors!!
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Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

- Easter
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Re: It just looks like trash!
Good thing I bought a 7" headlight. This is going to be a lot to stuff in! http://www.ngwclub.com/forum/posting.ph ... 30&t=46091#
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Last edited by Easter on Wed May 14, 2014 4:20 pm, edited 1 time in total.
Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

- Easter
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- Posts: 3007
- Joined: Thu Sep 13, 2012 11:33 am
- Location: South of Houston 100 miles
Re: It just looks like trash!
Rear brake system is rebuilt, painted, mounted and bled. Seem to be fine, but it is still on the lift so it isn't a sure thing till I get it on the road. Ordered and received today the complete Dyna S electronic set. Will probably start on that this weekend. Put a new battery in and nothing caught fire! When I turned on the key the light bulb for the gas gauge lit up. I called that success and turned the key back off. Haven't sorted out any of the wiring yet so didn't want to risk frying anything. I have been putting off the cosmetics till I get her running. The biggest issue after the wiring (that I know about now) will be integrating the seat/tail section. Once that is worked out I will start the prep for paint. The end is in sight but a few more hurdles to jump.
Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

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Re: It just looks like trash!
You're making steady progress, that's what it takes.
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Re: It just looks like trash!
There is a ton of room in that headlight bucket. It looked full stock, and then I added many wires and three relays and it still all fits fine.
Proud member of the NGW Cartel (Rochester MI)
1977 GL1000 BADDOG (April 2012 BOTM)
1976 LTD - '993 LTD...and so it begins'
You should remember that it's peace of mind you're after and not just fixing the machine. R.Pirsig
1977 GL1000 BADDOG (April 2012 BOTM)
1976 LTD - '993 LTD...and so it begins'
You should remember that it's peace of mind you're after and not just fixing the machine. R.Pirsig
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Re: It just looks like trash!
We were exploring east Texas this weekend so I didn't have much time to work on the project but I did manage to get the Dyna S module installed and wired. I have to assemble and install the coils next. I guess I will cut the leads from the old coils in order to keep the color code and the bullet connectors. I don't know the history of the old coils but they don't appear to be faulty. I just want to freshen everything up and hopefully reduce the number of issues to trouble-shoot when I finally put gas in it.
Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

- Fred Camper
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Re: It just looks like trash!
Old coils are often fine on dry days. Not until you are out in a downpour do 30 years newer coils seem like a great idea. Hairline cracks if present are not your friend.
Proud member of the NGW Cartel (Rochester MI)
1977 GL1000 BADDOG (April 2012 BOTM)
1976 LTD - '993 LTD...and so it begins'
You should remember that it's peace of mind you're after and not just fixing the machine. R.Pirsig
1977 GL1000 BADDOG (April 2012 BOTM)
1976 LTD - '993 LTD...and so it begins'
You should remember that it's peace of mind you're after and not just fixing the machine. R.Pirsig
- robin1731
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Re: It just looks like trash!
Fred Camper wrote:Old coils are often fine on dry days. Not until you are out in a downpour do 30 years newer coils seem like a great idea. Hairline cracks if present are not your friend.
Even on dry days they can be bad enough to cause issues. Better to replace and be sure. IMO
1976 Goldwing Super Sport
1985 Honda Elite
1976 KZ900 Dragbike
1992 ZX7 Dragbike (KZ900 style motor w/NOS)
and a rotation of various purchases
Randakk approved Carb Rebuilder
1985 Honda Elite
1976 KZ900 Dragbike
1992 ZX7 Dragbike (KZ900 style motor w/NOS)
and a rotation of various purchases
Randakk approved Carb Rebuilder
- Easter
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Re: It just looks like trash!
Yes, I already have the new Dyna coils and plan to use them, just kind of hated to cut the leads off the old ones to keep my color codes correct since as far as I knew there was nothing wrong with them.
Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

- Easter
- SUPER BIKER!!!!
- Posts: 3007
- Joined: Thu Sep 13, 2012 11:33 am
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Re: It just looks like trash!
Today after work, I mounted my new shocks and the Dyna S coils. Haven't wired them up yet other than attaching the short leads to the coils, but hopefully will get to that tomorrow. I can't keep putting off getting into that rats nest of wiring. Not too many other items left to deal with (actually still a lot but the options are narrowing down). Will try to get an updated photo or two tomorrow. Not much to show except those shiny new shock absorbers.
Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

- Easter
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- Posts: 3007
- Joined: Thu Sep 13, 2012 11:33 am
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Re: It just looks like trash!
Coils wired in, coolant in radiator, breather box and air filter back on, --can't put off the wiring much longer!
Question for users of Dyna coils, the instructions say (and Octane confirms) that the ballast resistor is no longer needed, and the wires going to the resistor can just be connected together. I assume that the leads straight out of the harness that went to the resistor are the ones that can or should be plugged together since the actual wires on the resistor are just short extensions that need not be used any longer? This is a little hazy for me as the bike was already disassembled when I started.
Couldn't find the camera this evening or I would have included some photos. Maybe tomorrow.
Question for users of Dyna coils, the instructions say (and Octane confirms) that the ballast resistor is no longer needed, and the wires going to the resistor can just be connected together. I assume that the leads straight out of the harness that went to the resistor are the ones that can or should be plugged together since the actual wires on the resistor are just short extensions that need not be used any longer? This is a little hazy for me as the bike was already disassembled when I started.
Couldn't find the camera this evening or I would have included some photos. Maybe tomorrow.
Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

- Easter
- SUPER BIKER!!!!
- Posts: 3007
- Joined: Thu Sep 13, 2012 11:33 am
- Location: South of Houston 100 miles
Re: It just looks like trash!
Here are a couple of photos. Not too much to show but she is coming along. Mounted the headlight bucket in anticipation of sorting out the wiring. Need to pick up some smaller bullet connectors since the ones I have are too large and I don't want to do anymore to the original harness than is absolutely required.
You do not have the required permissions to view the files attached to this post.
Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

- Easter
- SUPER BIKER!!!!
- Posts: 3007
- Joined: Thu Sep 13, 2012 11:33 am
- Location: South of Houston 100 miles
Re: It just looks like trash!
Thanks to a NGW member I acquired the hard to find bolt for the right foot peg and attached that tonight. Small but important! Started on the wiring, located the proper bullet connectors and clipped off the unusable connectors. Didn't get far but the starter button works, which is a good thing because it also confirms the replacement starter also works!
Bikes at present:
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process
83 XL 600r with a 2004 XR650L engine
And a slightly worse for the wear BMW GS adventure bike awaiting repair
83 GL in process

- Lefty
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Re: It just looks like trash!
You are doing a good rebuild. Thanks for all the photos and info.
Been riding Hondas since 1964.
Current bikes:
1985 GL1200i work in progress.
2002 CB750 Nighthawk
Current bikes:
1985 GL1200i work in progress.
2002 CB750 Nighthawk
- Roady
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Re: It just looks like trash!
An amazing rebuild ... considering where you were 3 months and 2 weeks ago (Feb. 10th).
