My build (another one)

[Denver]

Self made special tools have a sense of satisfaction every time you use it. :yes:

 

[ianstaley]

Hi all I have a serious problem to contend with, when I first started to strip out the bike, my front brake callipers were totally shot. I did everything to get the old pistons out I spoke with one restorer (a Pro) and his solution sounded a bit drastic, but he assured me if you could get the pistons out then the calliper would be recoverable, his solution after heating and lots of other stuff even after two weeks soaking in diesel, was the most drastic, drill a hole about 3mm in the calliper from outside inwards. Then use a small 3mm OD steel drift and beat the bugger out.

His reasoning was sound, once out the hole could be welded shut and cleaned up, but the cost was a bit extortionate. So I got another set of callipers of a guy in Canada, who said they came of a GL1000 1979. As I have said somewhere else on here, my registration docs states a K3. Now after buying the callipers the pistons were free, s great and cost was about 1/3 of the drilling/welding route.

Now comes my problem, I am looking at replacing the pistons as a matter of course and all the seals. But I am wondering if in fact I have GL1100 callipers. Looking at new callipers on Ebay I find that the greater majority of pistons come in a 38x35mm. The pistons I have are 43x41mm So the question is do I have the right Callipers for my discs? According to my Haynes manual the outside service limit of the piston is set at 1.5001" the pistons I have just measured are 1.688" measure on my 1-2" micrometer. I am thinking that these callipers are in fact off a GL1100.

The next thing is the rear calliper is a twin piston brake, are they all the same size or do they also differ in size. :help:

 

[mcgovern61]

Post a pic and we can tell right away if it is from an 1100.

 

[mcgovern61]

BTW, if you need new pistons, Wingovations has them:

https://www.wingovations.com/

(And he is located on your side of the pond!)

 

[ianstaley]

Okay so here are 3 pics of the calliper which imo are same as the gl1000 (in looks then). You can see the size of the piston from the ruler, take it from the 10 Centimetre line and go backwards. I always go things ar*e about face.

Yes I have had a look, that is why I doubt the callipers they say the GL is an 1100 well for my year then..

 

[mcgovern61]

It looks like a caliper from a '79 GL1000. Here is a site that shows new pistons with the measurements and the '79 GL1000K3 appears to have the 42.8 mm OD.

https://www.proebstl.net/pistons.html

 

[ianstaley]

mcgovern61 » Wed May 20, 2015 3:35 pm[/url]":gjximgwf]
It looks like a caliper from a '79 GL1000. Here is a site that shows new pistons with the measurements and the '79 GL1000K3 appears to have the 42.8 mm OD.

https://www.proebstl.net/pistons.html

That is great 20 seconds and they are type 2 pistons. Thanks sooo much. Ian :yahoo: :rocks:

 

[ianstaley]

So spent another hour or so on the strip down today, I am also in agony, I have the feeling that I have either bruised or broken a rib, I haven't, not been hit or fallen or stumbled into anything, but I awoke yesterday with a sore back, there is a red patch that is lumpy and it itches like mad, this morning another lump and still the feeling that I have had my ribs kicked.

Anyway back to the bike. So I managed to get the front wheel off and the forks out. However, something I have never seen on a bike I have valves in the top of the forks, undo the cap and sure enough there is a valve in there depress the little pip and hey presto a small amount of "air" comes out. So is this normal?

Got the triple tree off, so the front of the old frame is now free. I still can not find the circlip in the swinging arm at the engine end. It doesn't come out and the other end the circlip is to be seen. But too deep for my circlip pliers. I got some new ones I will make a picture later as I need to take the dog out, so when I get back it will be picture time.

Till then Ian out.

 

[ianstaley]

New Circlip pliers...

 

[Ansimp]

Nice operating tools Ian :good:

 

[julimike54]

ianstaley » Today, 1:42 pm[/url]":r2m1e0ei]
Anyway back to the bike. So I managed to get the front wheel off and the forks out. However, something I have never seen on a bike I have valves in the top of the forks, undo the cap and sure enough there is a valve in there depress the little pip and hey presto a small amount of "air" comes out. So is this normal?

Front & rear air suspension :good:

 

[toytender01]

They look toooooo purty to be used, should be framed and hung on the wall :smilie_happy: :smilie_happy:

 

[ianstaley]

julimike54 » Sat May 23, 2015 1:36 am[/url]":8oebss8o]

ianstaley » Today, 1:42 pm[/url]":8oebss8o]
Anyway back to the bike. So I managed to get the front wheel off and the forks out. However, something I have never seen on a bike I have valves in the top of the forks, undo the cap and sure enough there is a valve in there depress the little pip and hey presto a small amount of "air" comes out. So is this normal?

Front & rear air suspension :good:

Not on my GL, the rear are just normal, they have a ring that will adjust the hardness. I went to CMSNL and checked out the parts cat there, no GL 1000 shows with that small valve, which is why I thought maybe they are off a GL1100.

It wasn't a lot of air, just a week phuuuft, lasted all of 1/2 a second. The insides of the forks GL1000 and GL1100 look the same, with springs and so on. So not afraid to reuse them.

So thanks for the reply....

 

[ianstaley]

toytender01 » Sat May 23, 2015 2:42 am[/url]":15ju7z60]
They look toooooo purty to be used, should be framed and hung on the wall :smilie_happy: :smilie_happy:

Don't know about too purty, but the ends are a bit big, nice bag though, I will have to file the ends down other wise they wont fit. I think these were meant for BIG trucks.

 

[ianstaley]

Got the front wheel in house and took off the disc's, teh bolt M8 x 100mm are extremely rusty and I needed a drift to get the last two out. I will be buying new ARP bolts and SS M8 flanged nuts, now there are 5 more bolt with nuts that hold the spokes of the comstars to the aluminium hub. They are also in a dreadful state.

Any opinions here would be helpful. I have taken a couple of shots of the wheel hub, you can see the state of it. I will be vapour blasting these so that I can powder coat them or chrome them probably PC them, easier and cheaper.

My question is, has anyone ever removed these bolts, will I damage the wheels.The nuts and the bolts are suspect seeing as the bolts that hold the discs are too rusty for reuse.

It isn't my intention to remove the spokes just vapour blast it all.

 

[slabghost]

I'd be more inclined to find a better wheel myself. With so much corrosion the spokes are suspect where they meet. You are of course the best able judge having them there in hand.

 

[Ansimp]

If they were mine and they seem sound I would get them blasted and powder coated :yes:

 

[ianstaley]

I intend to get them blasted anyway, before I make any decision. I think I will replace the long Nut's and Bolts that hold the Brake discs on. I can get some ARP M8 x 100 stainless steel bolts which will be more than adequate to hold them on. I was going to do the same with the smaller ones. Swap them out 1 on 1.

The corrosion you see is an the hub it self, being aluminium this will in all probability be surface corrosion. I have two blasters here small DIY one that is a plastic box to hold the media and a gun. I also have a 13cfm compressor. The other one is a proper cabinet that would just take the wheel but I will have to assemble that first. So I though I might have a go with soda blasting, if that doesn't work then I can ship it off to a specialist. I dis ask earlier if anyone had ever stripped one down to its components. The consensus was don't do it. So I won't, but if the wheel is too bad to recover then I might just do it as an exercise, at that point I would have nothing to loose.

Thanks guys as always welcome comments.

 

[ianstaley]

Can I get back to my forks, below are a couple of photographs of the top of my forks. you can clearly see the valve. now as far as I am aware no GL1000 had air shocks either front or back. bearing in mind mine is between a 78 and 79? unsure of bike K3, KZ?

There are no connectors to the valves and no pipe work either. So what the hell is going on here, looks to me like for some reason someone has swapped out the forks at some time. I need to deal with this ASAP, so either new forks or how do I service these ones. As you can see, there is no way into the fork from the top. Can I assume that the fork is stripped from the other end? Where do I fill the thing with ATF etc. You can also see that the valve is damaged on this leg.

 

[julimike54]

Somebody take the filler plug out & add air valve (maybe)? Is there a P/N on the forks?