81 GS550T Full Rebuild...In Ohio

[cowboyup3371]

I'll give it a try Pete if I can make it back over to the garage tonight as I'm just now logging into work (love VPN systems - can do it from home). My only concern with that is how we didn't find any air in the system so I'm not sure if that will help. Not to mention this is a Kawasaki MC and not a Suzuki so will it act the same way?

[pete]

Scott, did you see my tip in the wrenching thread? Strap that brake lever back to the 'bar overnight and you should have a nice firm lever in the morning.

[Sci85]

No worries. Not too many of our projects here are perfect anyway. So post 'em up and let us enjoy!

[cowboyup3371]

Rebuilt the front master cylinder and rebled the brakes but they still don't feel perfect even with the fact there's no air coming through any of the lines. However, they still seem like they were last year so I'll make sure my first ride will be to a parking lot to check them out.

Also installed the rear turn signals and reterminated the ends but just as I was trying to run the wires through some shrink wrap this morning, work decided to call me in. Afterwards, my daughter had swim practice then the eldest had a Ohio Music Education Association Marching Band State Finals competition today where the team won a Superior rating (highest). I'm hoping I'll be able to go over to the garage tomorrow after doing some more work troubleshooting a phone issue we've been having with a vendor. Seems only the government cares enough to observe Veterans Day but as we've been fighting this problem for some time I felt we should get it done while the vendor was willing to work with us.

I'll probably forgo finishing the paint issues until later this winter so I can get a ride in before the weather gets too bad. So, just know what pictures I can take are not going to be great.

[Sci85]

Doh!

[cowboyup3371]

Remind me never to paint my own project again. Using the block helped me create an edge and go through the paint near the front of the tank. My friend says we can just feather and fix the paint when we are done but we have a long way to go still. I'm hoping for a ride and might do so before the paint is finished but am still debating on that since I am also waiting for a piston cup set for the front master cylinder.

[pete]

Awesome news she's running Scott, real glad to hear it!

[cowboyup3371]

I sure am learning what I don't like about powder coating. I stopped over at the garage tonight and adjusted the clutch the best I could after replacing the nut on the end of the adjuster. I then attempted to put the gear shift lever back on but the dang thing wouldn't slide into place very well thanks to the powdercoat placed there earlier this year. After taking the file to the post the lever sits on and sliding it back and forth I finally got it to sit properly. If I ever have to powdercoat a frame again, I'll make sure I do any taping, masking, and plugging of holes to ensure I don't run into the same crappy work these folks did. I'm also hoping the circlip will stay in place like it should as I couldn't find the groove it's supposed to sit in.

Front brakes are also in place as well as a new speedo cable I finally found. I ordered a new battery today as well as adjusted the chain.

What's left to do?

Finish sanding the tank and side covers
Make the new brackets for the rear turn signals as I'm missing one and the other is badly rusted
Mount the rear signals
Connect the wiring in the bucket
Recheck and tighten all bolts
Put cotter pins in places they need to be
Fill the brake reservoirs and bleed the brakes
Find the tags for this year and put on the license plate
Find a new hose clamp for the rear brake reservoir to master cylinder hose
Ziptie the wiring harness to the frame
Clean off the dust from the frame from sitting this last year
Fire it up again and go ride

That's about all I can think of for tonight although I'm sure there's more to do. A couple of more weeks should about do it if I can just get that tank done. The nice thing for this week at least is I have no reason why I can't make it to the garage - the kids are on fall break. I still have swim lessons Monday and Wednesday to get one kid to but otherwise no homework commitments

[tkent02]

Suggestion from experience: before you take that first ride double every fastener you can reach with a wrench. Wheels, forks, brakes, handlebars, EVERYTHING. Sometimes over the course of a year in the garage some things get overlooked.

Scott, I would ask someone like Steve to do this with you.

It's important.

[Sci85]

Feels good to hear that engine running no? A nice encouraging sound to help push you through to the end and create some excitement. Can't wait to see her with her new clothes on. Keep plugging. You are oh so close!

[cowboyup3371]

Thank you Ed. I was thinking about that over the last few weeks but I need to make some sign to reinforce the idea before I leave the garage. In fact, I put oil in it the other day and it was at a decent level right now for what I needed to do today. However, after shutting it down I realized I needed to add a bit more before I try to start it again. Once I tighten both wheels down hopefully tonight I'll pull it off the blocks, put it back on the center stand, and then get it done.

[Nessism]

Congrat's Scott. Looking good.

Suggestion from experience: before you take that first ride double every fastener you can reach with a wrench. Wheels, forks, brakes, handlebars, EVERYTHING. Sometimes over the course of a year in the garage some things get overlooked.

Can't wait for the maiden voyage trip report.

[cowboyup3371]

It lives!!!!

Had to go into work this morning to troubleshoot a phone recording problem for our nurse triage center but had a few minutes to stop off at the garage first. While there, I installed the rear brake caliper and new cushions for the rear fender.

After coming up with a decent working hypothesis of my problems at work and deciding I needed to do some reading on a possible fix, I stopped back over at the garage this afternoon. Although I am waiting for new exhaust gaskets to arrive on Monday from Parts N More, I happened to find one of the older ones originally on the bike from before the ceramic coating. I decided I would try to put the exhaust together today and after some cursing and thinking, I finally got it in:



My friend suggested I start the bike up and despite not being totally ready mentally (I wanted to do a few other things first), we grabbed the temporary tank, filled it with gas and pressed the button. Oops. Nothing happened so I checked the battery - was down to 6.5v. What the heck? We put the charger on it and then using my truck's jumper cables we jumped the bike from my friend's lawn tractor and after about 4 turns, it finally roared to life. I let it run for about 5 minutes total as it took about 3 to finally come off of choke. As it sat there running, I think I was still in a bit of shock as it didn't sink in even while twisting the throttle - good response from it and the rpms didn't seem to hang although I did have to adjust the idle knob a couple of times. Another good thing - no obvious oil leaks yet and I'm keeping my fingers crossed I don't have any too soon.

I am a little concerned that after having been off the charger for about a week the battery was as drained as it was. Would the fact I hadn't reconnected all the connectors in the bucket cause it to drain like it did? I'm really hoping I don't have a problem with this battery despite it having sat all year without being on the charger and not connected to anything.

Either way, I'm thrilled it's finally running and am looking forward to finishing up on the paint soon so I can get it out on the road.

Wow, ain't that a pretty sight, you have done a fine job there Scott, she is looking like a million bucks.

[pete]

Awesome Scott! Geez it feels good to get to that rolling point don't it?

And even though I can only make this comment based on one paint job so far, I agree it looks like sanding dust to me... rinse it off and you'll probably find you still have lots of orange peel to get rid of before hitting primer just like Tom said...