1980 GS1000S Reluctant Rebuild

[John Kat]

Thanks John, looks like I was doing it correctly, just need to modify the anvil to help it sit on the rivet head straight.

Here's the photos showing the pin just starting to go off center.

I've seen the pro's rivet a chain and they don't use a special tool to do so...
They hammer the edge of the protuding pin down carefully by supporting the other side with another hammer.
It takes some skill for sure to do it right!

 

[Kiwi Canuck]

If all else fails use a hammer (or two)

If all else fails use a hammer (or two)

I've seen the pro's rivet a chain and they don't use a special tool to do so...
They hammer the edge of the protuding pin down carefully by supporting the other side with another hammer.
It takes some skill for sure to do it right!

Looks like I will use that method as the rivet tool doesn't seem to have enough forced to flare out the rivet enough to make me feel comfortable.

Funny, I initially tried that way with 2 hammers, but I had not got the plates pressed together enough.
The chain tool was very good for pressing on the side plate without it going on too far and becoming too tight, as I used the anvil designed for that.

Certainly still worth having the tool and the quality is quite good.

Here's the picture.

 

[Guest]

Not real big on split links ?????
I've always used them and have had no trouble .

Cheers , Simon .

 

[Kiwi Canuck]

Not real big on split links ?????
I've always used them and have had no trouble .

Cheers , Simon .

Simon, I have nothing against master links and have had bikes with them for years, but when I ordered the new chain from Z1, I chose the one that needed riveting not realising that it would be this much trouble.

One of the guys in our local club who had a master link clip come off on his Kawasaki Z1 on a ride a few months back was lucky to stop before the chain let go, the clip had come off, which is rare but apparently does happen.

I used a sledge hammer as a back stop on the other side of the chain and peaned over the rivets by hand, it worked perfectly.

At least I can use the chain tool to change a cam chain or remove a drive chain if needed in the future.

 

[John Kat]

Not real big on split links ?????
I've always used them and have had no trouble .

Cheers , Simon .

I would never use a split link on a bike of this capacity

 

[Kiwi Canuck]

I think I'm covered.

I think I'm covered.

It's been almost a week since I posted and that's how long it's been since I did anything on the bike, kids birthday parties, social engagements and work have kept me a bit distracted from the project.

Not to mention riding the Boise Beauty, which I do as much as I can, I just love it and now that I've adjusted the handle bars and levers it's a lot more comfortable.

I went into the garage tonight to sort through a few parts to see which pieces I will put on the Canadian Cooley, which ones for the Boise Beauty and what are spares and what are for sale.

I want to get my application in for collector plates and need to get the bike completed for the photos, I considered just installing the stock pipes on the Boise Bike and using that but I will complete the assembly on the Canadian Cooley just for the photos and then finish the wiring details that I'm still working on afterwards.

I didn't realize I had accumulated so much stuff for the "S"'s, take a look at these.



Also got 2 spare fairings and a couple of nice consoles, (OK Simon just kidding about the consoles) would like to have a spare one though, I do have the fairings but they will need some work to be keepers.

A few spare mirrors, a gaggle of turn signals and two spare tail pieces, and plenty of left over parts in their Suzuki labeled baggies, but I've no idea what they are so I'll need to go one by one and look up the part numbers and see why I ordered them. Mostly screws, washers and spacers and misc. small parts.

Well back to it.

Cheers.

 

[Guest]

Bloody , bloody , bloody ................
I thought I was in there for a look , for a second .
I would near trade my left nut for a new console (and a front mudguard and a .......... ).
The only "spares" I've got are the $hit parts I replaced when I was doing the old girl up .

Cheers , Simon .

 

[Kiwi Canuck]

Project stalled still need more parts

Project stalled still need more parts

So I'm waiting on a shipment of parts from Boulevard, wheel bearings, a few screws and bolts and some other misc. items I can't remember, but I will hopefully have it by early next week and I can get it all bolted back together again.

In the mean time I thought I would do a little maintenance on my car which is a 2008 Mercedes ML320 Turbo Diesel.
I have always taken it into the shop because I didn't have the tools or the know how.
Today I went to the dealer and purchased the parts to replace the air filters (2 of them) and the fuel filter.
I needed to buy torx sockets as that what's used on this car, so off to Canadian Tire to find something, got a set of standard torx sockets as they didn't have their Maximum brand available.
They will do for now, but I will get a better set if I continue to work on this car.

First things first, find a You Tube video on the fuel filter change, watched that and was ready to tackle the job.

Got the first air filter out and discovered that the service techs who looked after my car had never changed the air filters as it looked pretty bad,.



Nice new original OEM filter.



Got them both replaced and the body work all bolted back together that needed to be removed to get the filter housings out, it took about an hour to get that done. then onto the fuel filter.

Here it is with special clips holding the hoses on, I did buy spares in case I destroyed the old ones when I took them off.



And the new one all setup and filled with diesel ready to go back in.




Got it all bolted back in and she fired right up, took it for a test drive and it's all good, about 1 hr 45 mins and saved about $400 in labour (and taxes) to change out those items..
Maybe I will do a little more on this car now that I've got the tools. (and You Tube)

 

[nikosg]

Want to send an E or S to me in Aus mate ??/

Lovely work by the way. very thorough.

 

[Fjbj40]

Isn't that comforting, you pay the "professionals" to take care of your car and pay the ridiculous price cause you want it done CORRECTLY and the f you over and don't do what you paid for, seems to be a common trend these days. I had a similar experience with Toyota earlier this summer with my 2010 4 runner. Needless to say I freaked at them and it got rectified but I no longer will let them do any work for me unless it is warranty work.

So I'm waiting on a shipment of parts from Boulevard, wheel bearings, a few screws and bolts and some other misc. items I can't remember, but I will hopefully have it by early next week and I can get it all bolted back together again.

In the mean time I thought I would do a little maintenance on my car which is a 2008 Mercedes ML320 Turbo Diesel.
I have always taken it into the shop because I didn't have the tools or the know how.
Today I went to the dealer and purchased the parts to replace the air filters (2 of them) and the fuel filter.
I needed to buy torx sockets as that what's used on this car, so off to Canadian Tire to find something, got a set of standard torx sockets as they didn't have their Maximum brand available.
They will do for now, but I will get a better set if I continue to work on this car.

First things first, find a You Tube video on the fuel filter change, watched that and was ready to tackle the job.

Got the first air filter out and discovered that the service techs who looked after my car had never changed the air filters as it looked pretty bad,.



Nice new original OEM filter.



Got them both replaced and the body work all bolted back together that needed to be removed to get the filter housings out, it took about an hour to get that done. then onto the fuel filter.

Here it is with special clips holding the hoses on, I did buy spares in case I destroyed the old ones when I took them off.



And the new one all setup and filled with diesel ready to go back in.




Got it all bolted back in and she fired right up, took it for a test drive and it's all good, about 1 hr 45 mins and saved about $400 in labour (and taxes) to change out those items..
Maybe I will do a little more on this car now that I've got the tools. (and You Tube)

 

[Kiwi Canuck]

Isn't that comforting, you pay the "professionals" to take care of your car and pay the ridiculous price cause you want it done CORRECTLY and the f you over and don't do what you paid for, seems to be a common trend these days. I had a similar experience with Toyota earlier this summer with my 2010 4 runner. Needless to say I freaked at them and it got rectified but I no longer will let them do any work for me unless it is warranty work.

fjbj40, thanks for your response, I have been intrigued by this topic as I run a serviced based business and I always try to make sure we offer good work and good value to our customers.

I am reasonably happy with the service I get at Mercedes Benz, including the nice lounge with the coffee machine and the awesome courtesy cars, but when I get the invoice I'm usually a bit shocked to say the least.

The warranty service, which I had two or three visits for small electrical issues relating to parking sensors and some safety restraint system was very good.

Not sure why the air filters were missed, it's not that difficult, but also not that easy to change out, as I needed to remove a few pieces of the engine compartment and the top part of the crossover air intake, but it should have been picked up during a maintenance visit, hopefully I never paid for it.

At those prices they should have pretty good mechanics working on my car, but they are probably just like a lot of the larger automotive/motorcycle dealerships were they have one or two very good well trained techs and the rest are either very inexperienced techs just out of some training school or just putting in time. Those are the techs who do the routine service work, which includes changing air filters.

Here's part of the problem as I see it.
For 20-30 years the trades were looked down upon and very few parents or teachers were prepared to have their kids look at a trade as a career choice.
It is changing now days with all the trade based reality TV shows which are bringing new blood into the trades and it's now being promoted by the main stream media. (not sure that's a good thing)
Not to mention how well paid trades people are compared to a university educated person working at a retail store or some junior position in a cubicle.
All those promises of "get a good education, get good marks and you will get into a good university was a big con job.
How long will it be before the new group of apprentices will become competent and proficient? Not sure but it's very hopeful for the future.

Things are changing so fast in my industry that I have to send my techs and support staff to training seminars and workshops for upgrading skills and knowledge, and almost every month we lose 3-4 man days to training, are other industries inundated with new technology that they can barely keep up with? Probably.
When we get a guy who grew up fixing stuff with his Dad and loves working with good tools, I am willing to spend what ever it takes to train them to become proficient in our industry, because they will be easy to train and will usually do an awesome job as they have the basics in their DNA.
When I interview new techs I always ask about what they love doing in their spare time,and what they did growing up for hobbies, (if it's playing video games, the interview will be over within a few minutes) and I ask them to bring their personal tool kit in to the interview.
I can tell a lot by what brand of tools they use and the condition of their tools.

Rant over,

 

[Kiwi Canuck]

Want to send an E or S to me in Aus mate ??/

Lovely work by the way. very thorough.

Sure, send me your address and I'll send you over a few.

Actually, you may just want to go visit Ozman, I hear he has a few spares.

Thanks for the compliments, they are always appreciated.

Cheers,

 

[Charlie G]

You have applicants that have tool boxes? I'm lucky if they have a drivers license and no DUI's.

 

[GregT]

You're dead right about the big gap in the trades educated people. I'm old enough that over 50% of the guys i was at school with went into trades straight out of school - probably similar to you, Dave. From the 80's on at least in NZ, it seems as though more than 50% went to university and from that point less went into apprenticeships or trades training.
It was seen as the alternative - and less desirable - path as guidance counsellors asked "do you really want to get your hands dirty ?"
What they should have been saying was "where there's muck there's brass!"

And yes, when hiring I've always asked about outside interests and made some surprising discoveries too. Some useful even....

 

[gs58]

Interesting to hear about your vehicle servicing (or lack of). My neighbour (single father) had two Audi's, a Q7 as a work vehicle, and a sedan for weekend driving (the one with the V10 Lamborghini engine). After taking the sedan in for servicing he was told that all of the brake rotors needed to be replaced. He wasn't surprised by this as he does a few track days and drives it reasonably hard, but a few days later he met the mechanic who had done the work outside of work hours and was told that the rotors didn't need replacing, that they were less than half worn, but he was instructed to replace them anyway. Needless to say my neighbour no longer drives Audi's. The Audi dealership refunded the $8,000 for the rotors, and bought both his vehicles from at a very good price for him. I have since heard of similar practices with other garages - hard times, desperate measures?. I don't think that it is a common practice, but in is not an unknown one.

 

[nikosg]

Pm'd mate, just let me know the import duties and ill sort you....

oo who is Ozman? Is he in Melbourne?

Sure, send me your address and I'll send you over a few.

Actually, you may just want to go visit Ozman, I hear he has a few spares.

Thanks for the compliments, they are always appreciated.

Cheers,

 

[Kiwi Canuck]

Pm'd mate, just let me know the import duties and ill sort you....

oo who is Ozman? Is he in Melbourne?

Nope, he's in NSW.

Look him up in the members list.

 

[Kiwi Canuck]

Refurbishing a set of mufflers

Refurbishing a set of mufflers

I purchased a set of 1979 GS1000L original mufflers from a member and picked them up on Friday from my US mail drop.

I finally got around to unwrapping them today and was hoping they would cleanup OK with the intention of using them as a spare set for my Canadian Cooley or maybe for the Boise Beauty if I decide to run stock pipes on that bike.
I had heard the GS1000L pipe should fit the Cooley with minor adjustments to the rear bracket, so I will know for sure in a few days once I try to install them.

They are OK but # 1 header has a few dents in it so I will need to figure out how to resolve that.

Here's a look at them as I unwrapped them.





These are in need of a good cleaning.
First stop was my simple green wash station for a good soaking and degreasing, and a few parts into the Evaporust bin to soak.

Then onto the polishing wheel for a few laps and then the best polish I know of Autosol, applied by hand with a cheese cloth.

First one almost cleaned.



Getting there,







One of the headers in need of some polishing, I could leave it in Evaporust for 24 hours but the buffing wheel with white compound works OK for this area as it's almost never seen on the under side of the pipe.



Here it is done, just a few minor pits left but plenty good enough.



That's about it for now, I'll update when I get them fitted and let you know how the fitting goes.

 

[Fjbj40]

All I can say is WOW! Hard to believe they are the same units!

Awsome job mister!

 

[Charlie G]

Very impressive polishing. I would have never thought You'd get it looking that good. Autosol hugh? I'll have to look for some.

cg