It's Home

Well, she's home... Now for the details.

Went down yesterday morning to work with Dude on the last bits and pieces and hopefully fire her up. So, first things first.. Lets mount some Rubber.

Started with the front, and changed the rubber. While we had the wheels off, and all that jazz we decided that it would be a good time to clean the forks up and all that fun stuff. So we set about that with emery cloth and fine sandpaper, then put a layer of clear. I think they look pretty good. Well, after that we went after the rear tire.

Dude isn't used to GS chain drives so I was able to demonstrate the easy way of getting the rear wheel off. (Admittedly, he claims the shafties are still easier.. Oh, well).

Well, while he was attacking the rear tire (literally.. ) I worked on re-routing some cables (or did I do this while he was attacking the front.. at any rate, re routed some of the control cable lines etc). Then I dumped some oil into the engine, and put about 2 gallons of gas in.

At this point we both attacked getting the rear tire back on the bike and the chain adjusted and all that fun. Approaching 4:30 in the afternoon by this time, so it was time to turn it over. Primed the carbs, pulled the choke.. Turn the key.. Crank.. Crank.. Crank.. let off to not overload the starter.. pop.. No lights.. Something isn't right.

Well at this point I had to get back as my Kitchen pass was a little overdue. Dude said he would attack the electricals today and give me a call with the results.

So, I get the call around 4pm today, found the issue, but we have another issue.. No oil pressure (look for post in tech section coming). Decided that at this point it is time to get the bike back into my garage and I can attack it at this point as our guts are telling us the oil pump is shot (was in the bottom end I picked up on ebay for $1, and if it was bad it may have caused the original engine to eat it, thus why the bike was parted out). So, I'm going to study some diagrams and see if there might be a clog elsewhere, but like I said, our guts say it is the pump is shot. Good news is I have at least 3 of them sitting here.

So, now were talking 5:00 pm and I am ready to load the bike.

Picture time..

Here it is sitting in Dudes driveway waiting on some lovin..



And here I am Smiling that my baby is back together, and coming home:



And here she sits in the garage, next to the beast..

Better angle (can't quite see the ripped seat):



Another angle.. (where you can see the seat):



So, next chance I get I'll dig through the boxes to find the oil pump from my original engine, then drain the oil and attack.

Hopefully I'll be riding her come spring (I don't doubt it much).

Dude's been busy

Well, as the title states.. Dude's been busy. He actually has the bike all together now, and sent some pictures my way so I figured I'd share them. There is still work to be done, brake lines need installed (calipers and master cylinders need cleaned as well), chain needs installed, exhaust needs securely fastened, and a few other small items. But here are the pictures:

Front fender installed with fork brace:


Front end Headlight and turn signals:


Guages:

And here is the bike all together, like I said, the exhaust isn't secured here, but mocked up, and there are some bits that need some attention to detail, cleaned etc, but it's rolling on it's own wheels at the moment:


I'll update as further progress is made!!

Update (with some back pictures)

So, Wednesday I have the day off and go down to Dude's place. And here is what I'm greeted with:

He's been a little busy, to say the least. But he's been enjoying it. (I really owe this guy.. )

Anyway, now for some backup. Here are some pictures he took of the assembly process, though not too many or any details as he was probably paying attention to them rather than taking pictures of them.

So, here is a close up of the cylinders ready for assembly:

And here is the lower half with pistons installed:

He also did a bit of cleaning of surface rust on some parts and here are some pics:

Peg mounts:

Passenger peg mounts:

Intake boots (the bolts have been replaced with some allens I bought for the purpose):

The wiring harness and electrics all run nicely:

Airbox with K&N dropin waiting for oil:

Just a couple more of what greeted me:

Ok, now for what actually got done on Tuesday. It really won't look like a lot, but it was. We pulled the side covers and tank to put asside for safe keeping. Then went to town. Worked together with a spare swingarm pivot bolt I had up here to remove the rotor from a spare crankshaft then installed it onto the bike along with the starter clutch and gears:

While Dude was buttoning all that down, I went through the electrics and hooked everything up that would normally be hooked to the front of the bike (controls, guages, headlight, etc) so that we could work on testing with the battery I brought from the 650. So, we did that testing, and discovered the replacement signals I have for the front of the bike are wired for running lights. Woohoo.. hold on.. my bike isn't wired for them. So Dude took a look at the wiring diagram and determined where we could pull some power for the running lights from, then went to work putting in the connections, as well as cleaning some PO (Previous Owner) hacks. So, as Dude was doing this I was working on cleaning the exhaust system, Not a pretty or fun job really, but they did clean up pretty well, though I forgot to get a picture. (oops).

At this point we needed a little garage break and needed to pick up a couple of small items, so off we went to pick up fuel line, vent tube line and a couple of small connectors.

When we got back I kept Cleaning them Dude also worked on putting the Carbs onto the bike, and buttoning all of that down.

Well, by this time it was getting close to time for me to head home, so I started boxing up extra parts to get them out of his way. In the process I found a bag of bolts and we decided to see if any of them were long enough to support the stock grab bar (rusty as it is). So I went through them and found a pair that were the perfect length. And here are a couple of pics of the bike how it sat when I left (we removed all the wiring stuff from the front for safe storage):