1982 GS300 Project - Where do I start

[Guest]

Holy crap! Cograts Jake!

 

[hjacobmiller]

Thanks Mechanix!

Wouldn't have been able to get this far without all the help you and Pete have provided.

Sorry I have been AWOL for a bit. Not much 'progress' to report since last time. I have been working a lot just like this time last year and I was waiting for a couple pieces related to the brakes to come in. I had to get new shoes for both front and back, new shoe springs, new cables and a lot of hardware...

So now I need to call on the wisdom of the GSR gurus again. As you can see in my last video it started perfectly, accelerate nicely and return to a normal throttle with no hanging idle issues. However, when I pulled it out yesterday to install all of the new brake parts, it wouldn't give me a solid start! Took full choke to get it to fire up, which for a 30 year old bike is to be expected...

But, after letting it "warm up" for a brief thirty seconds (didn't want to overheat it because obviously I wasn't riding) it wouldn't run with out the choke on.

What was even more frustrating is that it would stall every time I tried to roll on the throttle. Even just a bit!

So, the only things I have changed since the last time I worked on it are:

1. Installed front and rear brakes and hardware (guessing completely unrelated)

2. Installed tailight and license plate

3. Installed headlight

4. Installed front brake and clutch adjustment hardware.

So, needless to say I have no clue what it could be.

My thoughts are that it could possibly be unsyncronized carbs. But that wouldn't explain the change since last time since I have literally done nothing with the carbs.

My next thought was timing, but I brought out the timing light and everything seemed normal.

Any thoughts?

 

[Guest]

Good to hear from ya' Jake.

How long has it been sitting?

I'm wondering if the fuel's started to go off and is blocking the pilot circuit?

 

[hjacobmiller]

Good to hear from ya' Jake.

How long has it been sitting?

I'm wondering if the fuel's started to go off and is blocking the pilot circuit?

What do you mean started to go off? Like go bad?

I mean the fuel is probably about a year old, but I would think it was just as old when it ran fine three weeks ago?

 

[Guest]

Going off... going bad

If fuel sits for more than a few months there's a good chance it will start to go off and will start solidifying into the crap that blocks your carb passages.

I'd definitely be looking into that if it's been sitting for a year!

You'll probably find 3 weeks ago that you circulated the fuel enough to pull some cruddy bits into your pilot system.

Not sure if you'll need a full carby clean but at least take them out, take the jets out, and spray some carby cleaner through the jets and all passages.

It may still need a dip but hopefully not...

 

[hjacobmiller]

Hi Folks,

Just thought I'd give an update since its been a good 6+ months.

Ended up doing a dip on the carbs after these last posts. Problem solved, as usual when one takes the time to thoroughly go through the carbs proper.

Haven't done too much else with the project because I don't have a place to work on it in the winter time really. Unfortunately she sat outside all winter under a cover and a lot of the parts that I had polished up so well have gone to crap.

Have an issue to sort out with the front brake sticking a bit. Ordered a new cable and going to grease up the mechanical bits once the rain stops.

I did however take the tank to some local guys to have it derusted and sealed with POR 15. I don't have the time/space do it myself and since I want it done right I figured I'd take it to the pros. Hopefully picking it up this week and then off to the painters next weekend if I can get brake issue straightened out and pass inspection!

Cheers!

 

[Guest]

Nice to hear from you Jake and glad to see some progress is happening

 

[hjacobmiller]

Cheers Pete! Good to hear from you!

Tank derusting/sealing turned out great! A little $$$, but definitely worth it to have it done right.

Dropped it off at the paint shop yesterday. Had some sweet vintage green paint and a nice cream to go with that retro vibe. Hopefully should be done by next weekend!

In the meantime, I've got the following to figure out:

1. Front brake issue. I'm guessing I just need to throw some grease on the arm that comes thru the hub, oil the the new cable and make sure the cam timing is correct for both sides.

2. Figure out what to do with the gas cap gasket. It is dry rotted to hell and there is no replacement. I ordered a new generic gas cab from ebay (from HK and cost $20 US for a whole new cap) and am thinking I will take the gasket off it and put on the old cap so I can have just one key. Thought about making one myself but the shape of the original is so weird.

3. Definitely want to get new headers made (get rid of the link bar in the middle) and new mufflers. Need to search and see what I can find.

Getting so close!

 

[Guest]

I've got no experience with a drum front brake or a fuel cap with a gasket... but what you say sounds fair I think

Pipes... you have to get pipes just right, they can make or break the look for sure and of course you need to get them breathing right as well!

Can't wait to see some paint done

 

[hjacobmiller]

Slowly but surely making progress...

FINALLY got the front brake issue figured out. It just needed a bit of grease on each post coming through the hub and they release fine now. I was worried some had gotten jammed up during the last time I had the front wheel off.

Had ordered new rear shocks from MikesXS and they had the GS300 listed for a set and I ordered them. Well, unfortunately they were about an inch longer than the stock (I measured mine but through that maybe they were just so worn out they had compressed that much). There was no way I could leave the new ones on because the bottom of the shock would have busted into the muffler if my back tire went through a pothole or otherwise fully extended the rear shock.

Sending those back tomorrow. Such a pain, but better to get it done right than to have issues further down the road. Got another set that is the same as the stock.

Still waiting on an order I placed from Boulevard (now PartsOutlaw?). I ordered it almost three weeks ago and the new girl they have running the online orders isn't nearly as helpful as Brent used to be.
Any who, according to them the parts should be shipped tomorrow and to me by this weekend. Got a couple small things, nothing major but things I wanted to replace.

Have to figure out what is going on with the rear brake light. It works when I push down the pedal, but the running light is out. I changed the bulb so I think it is the wiring mechanism. That will be included in my Boulevard order when it arrives.

And now, the part you all have been waiting for. *drumroll please....*

PAINTED TANK AND PANELS!!!









Can't wait to get these last few things buttoned down so I can ride!

 

[nelson]

I like it a lot! LOOKING GOOD! :clap:

I'm working on a GS300 myself right now, and mine looks really rough in comparison... Bare metal tank and bike didn't come with panels... That paint came out really nice!

Let's get that thing on the road! :dancing:

 

[Guest]

Excellent Jake! That paint job looks awesome! :clap:

 

[hjacobmiller]

Cheers guys!

Pretty excited. Received the knock-off gas cap from China this week, the extra shocks and FINALLY got my order from Boulevard!

Any suggestions as to why the tail light may not be working but the brake light works fine? I know it is a combo bulb, but I put a new bulb in but still no luck. Just put on a new brake light switch so that isn't the issue. Looking at the schematic it looks like it might be something in the ignition switch?

Other than that I think the final touches should go pretty smoothly tomorrow to get it back up and running. I know I will need to get the tail light fixed before inspection, but hopefully everything else should be fine!

More pictures tomorrow...

 

[Guest]

Good stuff Jake!

Are you doubly sure the bulb is the right one? I seem to recall something funny with bulbs in mine and I didn't have the right dual filament one, but that was way back in about '98 or '99...

Can't wait to see her all in one piece!

 

[hjacobmiller]

Drummmm rollll...............

So, been a while since I've been on here. Unfortunately not much has changed on the bike, and it has not been ridden much due to a couple of reasons. First, have not taken the time to maintain it correctly (tsk tsk! no wonder my forum level has dropped to Newbie) and the carbs have gunked up, fuel gone bad, battery dead, etc. This is mainly because of the second reason, which is that I have added a few horses to my stable (a garage now instead of an apartment parking lot). A 2015 Triumph Scrambler, 1986 883 Sportster (inherited from Grandfather) and a 1974 Honda CB125 (inherited from a family friend.)

But, I am back to tinkering on the Zuke!

My first move was to cut the stock exhaust cans off because it just isn't breathing right, and hasn't been, ever. Even it's best of days running a couple years ago, it always felt bogged down. So, a quick trip to Harbor Freight, $30, and a cutting wheel later, the cans are cut off with enough of a stub to put some other slip ons (probably EMGO 12" Shorty). (pics later tonight).

With my new found friend, the cutoff wheel, in my hand, I'm reaalllly tempted to start tearing in to the seat mounting points to get at mounting a flat "brat" style seat... But, if my millions of hours spent on the GS Resources have taught me anything, it is to learn first and cut second.

Does any one have a good post about attaching a flat seat? I have a material in mind for the pan, but really can't put together an idea in my head about how to attach, especially at the front where the hideous "L" king and queen slides over to cover the tank mounting bolts.

More pics later about what/where I'm thinking about cutting, but I'm just so anxious to get input I couldn't resist posting on the lunch break.

Appreciate anyone still subscribed to this thread. Really looking forward to getting back into this bike. They say you never forget your first...

Best,
J

 

[Guest]

Mate glad to see you're alive! I was just thinking of your 300 the other day and whatever happened to it...

Can't help you on your seat unfortunately, I'm still running the stock pan on mine and when I make a custom pan for it soon it will stick use the stock mounting setup. By custom I just need to make it a solo seat as insurance is a hell of a lot cheaper here.

How does the Scrambler go? I got a thing for those...

 

[hjacobmiller]

Good to be back, Pete! Your bike/craftmaship is still the standard I hold my work to!

So, here is how I want to modify the frame:



Cut the stock seat support away, and then bolt a strip across the back where the turn signal bracket mounts are. Then, I can put a single mount in the center (center hole) for the fender which I plan on "bobbing" back significantly. The two holes on either sides would be for the seat pan. The side bolts on the fender would be unchanged and provide the same support so the fender doesn't rock to and fro.

Does removing the stock seat support cost me any lateral support? I know a lot of folks will weld hoops on the back, but not really an option as I don't know how to weld or have a welder. Is it dangerous to remove this?

The part I'm really having trouble with is the area at the front, which I have no idea how to do tastefully. I'm not opposed to leaving the tank mount bolts exposed, but then I don't know how secure the front of the seat. The stock seat has a tongue/fork set up so that the "nose" of the seat slides over the tank mount. I'm just having a mental road block.



Any suggestions?

The Scrambler is a blast Pete. A big step up from 300CC to 900CC, but what a difference in comfort and can't replace the reliability of fuel injectors! Although, it is a whole new type of scary when it comes to tinkering though. PM me if you want a link to my Triumph forum thread (which hasn't been updated in a while since I've been riding too much to type!)

Thanks,
J

 

[Guest]

When I initially was planning my build, I also planned on removing that seat brace before deciding to stick with the stock pan and lock setup.

What I did find out though is that piece of steel does nothing for frame integrity and does not appear to do anything except give the seat pan a place to rest on. Someone posted a Youtube video at some point of someone grabbing one that had been cut off and twisting it in their bare hands, so that's not going to provide any structural strength at all.

As for the front, can you get a pic of the bottom of your seat pan?

My suggestion is do something to cover those tank bolts... if you do manage to slide forward off the front of the seat for some reason... well...

And yeah shoot me a link to your Scrambler thread for sure! They do look like a hoot although I think I'll be sticking with my old Zuk's for a while yet. My Kat is my dream bike so she should keep me satisfied for a while

 

[hjacobmiller]

Bending in your hand? Jeez, I didn't realize it was that flimsy! Good to know that I won't lose any thing by getting rid of it though. Thanks for the input.

Here is the front:





Not sure how to replicate that. I'm planning on using some large composite cutting boards I found at Walmart for about $6 a piece as a pan.

I just really can't think of an aesthetically appealing way to attach to the front! I keep getting hung up on how to attach it while having the front of the cover be stapled down to the pan.

On a side note, my buddy just picked up an 82 GS450 for $80! Looks like there is a lot missing and the engine is possibly seized. If he can't get it to run, he's going to part it out. The tank is clean and not dented though so he'll be able to get his money back probably with that alone.

Why I'm even bringing this up is because it has spoked wheels and a front disc brake... Methinks I could grab the hubs, forks, and calipers from him and have a disk brake on the front.... I'm assuming the hub is the same width and the axle's are the same, would have to look at part's fiche. This way I could get the awesome symmetrical wheel look and upgrade the braking capacity...

Thoughts?

Pete, I think you're the only one I'm talking to haha.

 

[Guest]

I guess the big question is what are you trying to achieve? If you just want a lower profile seat, then maybe just trimming the foam on the stock pan will work?

If you want an absolutely flat seat, then yeah that gets a little tricker...

However, it looks to me like if you use the rear mounts on the frame for the rear of the seat, it's going to sit above the frame rails a similar height to those mounts at the front anyway, so maybe replicating that front mount setup is the way to go.

You could always mould some fibreglass around the mounting posts on the frame (make sure to use a release agent!) and attach that to your seat base... or you could just make the seat base out of fibreglass.

I can't offer a lot of tips in this area just yet because I haven't even started on mine...

As for the front end, yes there's a very good chance it's a direct swap. Looking at the triple clamp parts numbers on the fiche may give you the answer there, or maybe even just checking against the steering head bearing part numbers.