1982 GS300 Project - Where do I start

[hjacobmiller]

Checking in...

Still haven't figured out the seating arrangement, but have done a little bit of tinkering here and there.

1. Recently purchased pod air filters and removed the airbox. GASP! How dare he?!?!? It will be a nightmare to dial in...
Pods are K&N RC-1060. Inlet measurement ~50MM. $21 USD/each
2. Purchased Six 6 Jet Kit and just finished installing the shims on the needle. Piece of cake and everything else is just a direct screw in swap for the other jets.
$55 USD shipped. Really fast shipping and seemingly easy to install. I don't know the running results yet, but will review once complete.
3. Running into trouble with the kickstand/centerstand with the EMGO shorty's. They're just a bit too fat to let the stands close completely. More to come.

Might throw some pictures up later.

Cheers,
J

 

[Guest]

Good to hear from you! Would be better with pic's of course

Interested to see how you go with the jet kit... many mixed reports from there.

For the stands, you can always add a larger rubber stopper depending on how low they're getting held down. You don't wanna scrape them in left handers...

 

[hjacobmiller]

Back after another hiatus...

Scrapped the EMGO shortys. Too much of a pain. Made a "custom" exhaust with some 1.625" pipe, internal baffles and VW exhaust tips...











Was going to buy a welder and teach myself, but unfortunately don't have sufficient 20 amp circuits in the garage. Fortunately a neighbor up the street (who has an amazing KZ1000) has previously offered to do some work for me.

Just need a couple beads at the joints for this, although with how tight the I/D of the straight pipe and O/D of the headers fit, it may not be necessary.

Took a short video:

http://vid1256.photobucket.com/albums/ii481/hjacobmiller13/IMG_1572_zpsdfafpxlf.mp4

 

[hjacobmiller]

Also, relocated the R/R and starter solenoid to the battery "box." Made all new starting/primary circuit connections and routed wire more cleanly, IMO.





Eventually this "tray" will get plasti-coated and house the motogadget munit, and I'll be able to get rid of the rat's nest of wiring currently ziptied to where the headlight should be...

 

[Guest]

Glad to see the 300 being worked on again! Nice work, and those pipes have a nice rorty sound to them... I like it!

 

[hjacobmiller]

Glad to see the 300 being worked on again! Nice work, and those pipes have a nice rorty sound to them... I like it!

Thanks Pete!

Anyone have a link to a good thread/video for replacing the clutch plates and springs for these bikes? Searched around a little, but didn't find one that answered all the questions I have...

 

[Guest]

Can't help you on that one I'm afraid... my clutch was good when I dismantled the engine so I just put it back in. I'll have to do the Kat clutch when I get to that point but that's months and months away yet.

 

[hjacobmiller]

A couple more updates. First off, I got a welder!

A friend of mine welded the hoop on. Notice how we cut away the original frame tubing to utilize some stability from the shock mounts.



Welded that mudguard in place too. Just starting out that was a bit of a challenge for me. But, nothing a 60 grit flap disk can't fix.






Mock up of the tail light and cross bar for seat mounts.



The seat pan, about half way done.







A couple magnets holding it in place. Need to trim the back because I didn't take into account the curve when measuring the length of the seat.

Thoughts?

 

[Guest]

Nice work Jake, I like it! What sort of welder did you get? I've been using a MIG here now and it's so much better than the stick welder, although my stick welding has improved a lot compared to when I started... still nowhere near pretty though...

 

[hjacobmiller]

Thanks Pete!

I bought a combo unit. The ESAB Rebel 215. It has MIG, TIG, and stick processes. My brother is a salesman so had some employee discounts to help offset the sticker shock.

Worked a little more on the seat today, but didn't take any pictures. Will try to take some tomorrow after I've had a chance to get a little more work done.

 

[Guest]

Ah nice! A mate I used to work with bought one of those but out of my price range unfortunately. One day though, one day!

Looking forward to the update!