My 77 GL 1000 project with a capital P

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Terry

Well-known member
Joined
Mar 24, 2015
Messages
548
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Location
Houston, Texas
Up until now I have kept no log of services or dates
The following repairs were done between 08-15-15 and 09-12-15

Replace timing belts check tensioners
Replace upper and lower radiator hoses and thermostat
Test cooling fan, a ok
Replace steering head bearings
test horn/ok
Install new clutch cable
Install new choke cable/control
Install new push and new pull throttle cables
Derust fuel tank repaint exterior
Redd Kote fuel tank
Clean fuel pump diaphragm etc.
New petcock
New fuel lines
New Randakk high performance fuel filter
New spark plugs
Clean all switchgear switches
Replace hand grips
Clean repaint muffler system
Clean and lube ignition
Carb overhaul underway along with many other tedious little spruce up chores
 
Sunday 9-14-15

Remove tire, rotors, axle, speedo drive from front wheel,
Clean and refurbish wire wheel, ready it for new tire.

Refurbish rear signal assembly straighten bar, polish, touch up all, test lights, prep for install.
Rewire signal lights properly with clean grounds, insulated solder joints, and bullet disconnects

Clean up and organize the zoo of a garage workspace to be less hazardous and more productive.
 
09-16-15

Returned this p.m.

Got several parts in

Located tubes and rim bands locally

Changed final drive gear oil, Valvoline Full Synthetic 75-90 (Honda moly 60 gear spline lube ordered)

Filled cooling system with Honda premium 50/50 coolant, will purge after startup
 
09-18-15 & 09-19-15


Refurbed tail light (new lens ordered), signal light, license plate bracket, and put together rear fender as an assembly
Refurbed rear wheel and removed old tire
Clear clog from fuel tank reserve tube, cleaned and treated
Installed forks, headlight, front turn signals, etc.
Clean up and deglaze rotors
Put new Dunlops on the wire wheels
 
09-25-15

Installed rebuilt carb rack (Randakk kit)
Installed derusted and coated fuel tank with new petcock
Installed inner fender and rear fender taillight license plate assembly and seat brace
Cleaned and painted battery tray and electrics attached to it
New battery
installed false tank connected electrics

Brake parts on order
 
Not much today 09-27-15

Refinished air cleaner installed it with a new air filter
installed Randakk high performance fuel filter
new hoses for air cleaner, fuel overflow, breather waste container, fuel system total
rebuilt front master cylinder, new fluid cup, (what pain, that thing was nasty}
attached new brake line from MC to splitter

put mirrors back on
battery in, all lights, blinkers tailight and brakelight rewired and tested a-ok
installed new taillight lens


Found exhaust headers rotted away at connection joint, removed and ordered some used ones on Ebay
Wet sanded compounded and polished false tank
 
10-03-15

Installed new front brake lines
Installed front fender and wheel/new tire and speedo cable
Installed reconditioned brake calipers with new pads
Installed seat bracket and seat
cleaned up chrome rack and backrest and installed
lubed final drive splines with Moly 60 Honda assembly lube
installed shocks
installed rear wheel/new tire
installed reconditioned rear brake caliper with new pads and brake line
disassembled cleaned and greased pivot for rear pedal then reassembled
tested rear brake switch (a-ok)
Rear master cylinder removed (must be rebuilt)
Cleaned and installed side covers


People we have a roller, soon to be a runner when the remaining parts come in.
 
10-08-15
Oh crap, I forgot to log some small things recently. Oh well maybe I'll remember what it was later.

Figured out how to repair OEM muffler connections, fabbed up proper reducers, painted, and installed.

Refinished and installed passenger pegs

Did first oil change for engine flush with A/T fluid and a dab of MMO to clean up galleys and internals
Installed new oil plug and washer, evidently P.O. thought vise grips were an all purpose tool.
 
10-10-15
Got parts in, rebuilt rear master cylinder installed filled and bled rear brake system.
Good firm pedal and lever, front and rear brakes like new and ready to rock.
 
10-15-15
Installed new tank badges
Did second internal 50/50 mix atf and oil ran engine up to operating temp and drained
Did final startup oil and filter change with Rotella 10W 40
Cleaned up corroded fuse and ground connections
Performed initial ride, as suspected running only on front two cylinders
Clutch plates stuck together and unresponsive, repair if it doesn't break loose to be determined
Restored braking system working perfectly
Diagnostics revealed:
plug wires and caps good, internal plug wire resistors good, but one coil had an open winding
Found reserve lighting module defective and performed bypass procedure

New coils, start/kill switches, hi/low beam switches purchased and being shipped
 
11-03-15

Installed Dynatek ignition, coils, and plug wires.

Test fire after installation and static timing: Finally runs on all 4 cylinders, starts instantly without any choke, idles great, and revs willingly and instantly.

Test ride soon. :)
 
11-18-15
Pulled ignition lock assembly replaced electical part of switch and reassembled it and tested, working good.
Corrected flaky left blinker wiring.
After used Ebay tach was bad I pulled apart original tachometer found the issue repaired and tested, A-ok PITA to reassemble and get flange correct



Note: around 11-11-15 clutch plates came unstuck (yea) after some dedicated effort to free them. Clutch is working right now and bike seems to run better with every mile it's ridden. 150+ miles ridden on it since test fire after rebuild.
 
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