Naked Cooley

[GS Jim]

Can you use the trick where you move the mud guard out of its holder and back to create more room for the aibox.. Works a peach on my 450..

Thanks for the suggestion, but the mud guard doesn't interfere with the airbox on the 1000, wish it did.... I gave it another try and gave up. I think the rubber boots on the airbox are too stiff.

Anyway, the bike was due at http://www.z1cycletech.com/ for dyno tuning anyway, so I just asked them to install the carbs & airbox. At the end of the day this is a hobby, so if it ain't fun, I'd rather pay someone to do it for me.

I did manage to reinstall all the other bits, so when it comes back from tuning, hopefully next week, it could be ready in a day.

When I installed the exhaust headers, I found the job could be made a lot easier if you tack glued the steel collars to the header end. Otherwise you really need 4 hands to keep everything lined up and in place as you push the headers into the exhaust ports.



I used CA type glue with accelerator that I used building my rc planes, but I suppose pretty much anything else might do too.

[Guest]

I put a couple of small pieces of masking tape around mine, figured it will just burn up. That bike of yours is going to be so sweet when you get your hands on it, make sure you do video!

[GS Jim]

I put a couple of small pieces of masking tape around mine, figured it will just burn up. That bike of yours is going to be so sweet when you get your hands on it, make sure you do video!

Thanks for the kind words AZR, I will definitely do pictures and might have Paul do a video since he has experience as a host on the Motorcycle Experience cable show.

[GS Jim]

She's baaaaaack!!

Well, it took a little longer than expected to get her running and tuned for the pods, but she's back together and running great. I still need to get tags and insurance before I can take her out for a proper drive, so the test ride report will have to wait.






Can't thank Paul Kahnert (aka doubleblue) enough for his help and encouragement, without which this project would never have come to completion.

[mrl1000l]

awesome, looks great!

[amxsteve]

Bike looks great. Can't tell in the last pic did they get the air box on? Tell us what it made on the dyno.

[jwhelan65]

Awesome build! except for those mirrors...

[steve murdoch]

Very nice, Jim.
And if you get a good deal on insurance we will need to know about it. lol.

[GS Jim]

Hey Steve, since you ask....... Z1 Cycle Tech was a great disapointment. They couldn't figure out why the bike only ran on 2 cyclinders and just told me they hadn't the time to fool w/ it any longer and to come pick it up. After looking here'n there and talking to a few other shops, I decided the guys at TO Cycle in Etobicoke were the right ones to sort it out.

They quickly diagnosed the problem as a fried ignition (Boyer) and replaced it w/ a Dyna. They also upped the jets to 115, if memory serves. Runs great now. They are old school though and don't have a dyno, they tune it by ear and by the plugs.

The stock airbox was ditched for pods. They could get 'em back on, but the rubbers aren't sealing anymore.

[GS Jim]

Very nice, Jim.
And if you get a good deal on insurance we will need to know about it. lol.

Argh, insurance - don't get me going, it's a scam up here in the great white north.

[amxsteve]

Hey Steve, since you ask....... Z1 Cycle Tech was a great disapointment. They couldn't figure out why the bike only ran on 2 cyclinders and just told me they hadn't the time to fool w/ it any longer and to come pick it up. After looking here'n there and talking to a few other shops, I decided the guys at TO Cycle in Etobicoke were the right ones to sort it out.

They quickly diagnosed the problem as a fried ignition (Boyer) and replaced it w/ a Dyna. They also upped the jets to 115, if memory serves. Runs great now. They are old school though and don't have a dyno, they tune it by ear and by the plugs.

The stock airbox was ditched for pods. They could get 'em back on, but the rubbers aren't sealing anymore.

Ralph would know a thing or two about these old suzukis. He raced a Kawasaki back in the day and will attest to the Gs pulling him out of the corners but quite equally matched for top end. He knows what he's doing. If you want it dyno run take it to cycle pro.

[amxsteve]

Argh, insurance - don't get me going, it's a scam up here in the great white north.

I just had my buffalo stocker and the wife's 400f appraised tonight and have been in contact with Dalton Timmis so if there is any savings I will post. Buddy at Dalton said he would insure the turbokat so it sounded promising. 6 insured bikes no discount=scam. My car is worth 5 times as much as my bike and I pay $325/yr.

[GS Jim]

Ralph would know a thing or two about these old suzukis. He raced a Kawasaki back in the day and will attest to the Gs pulling him out of the corners but quite equally matched for top end. He knows what he's doing. If you want it dyno run take it to cycle pro.

No doubt, it was fun talking to Ralph and hearing the stories about his racing days. His mechanic, Junior, did most of the work on the GS and it was perfect, 'cause he loves these old bikes himself (his daily rider is a KZ900 bored out to 1200).

[GS Jim]

Went for a proper ride up to Lake Simcoe on Mon and snapped a couple of pix.



Paul was on his 2 wheeled insanity certificate (aka ZX 14), which has been tuned for 195 rear wheel horse power.



I'm thrilled to have the Cooley back in operation. Carbs still need to some fine tuning (running WAY too rich, me thinks), but she is getting there.

[mrl1000l]

Carbs still need to some fine tuning (running WAY too rich, me thinks), but she is getting there.

vm28 with pods and a 4-1 header and only 115 main jet. If it's rich, I'd doubt it's the main jet.