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Clouds GS Restoration Log

One i got it apart, it wasnt TOO hard to get it together. One thing I DID do what take it apart and put it together with the headers mounted on the bike. Dunno if you are doing that or not, but it made things alot easier. If you're trying to get it together, i would suggest taking a piece of wood that is large enough to cover the whole area of the end of the meg and using the a mallet on that. Even the rubber one is likely to bend the end of the pipe up. You may have better luck also if you remove the baffle, then try getting the meg on and putting the baffle back in. Just a thought. Oh i do remember, getting it off, i did some twisting back and forth, using the welded on rear mount as a lever. Made it move much faster.
 
Yes, I ordered more parts tonight... Hopefully this will be the last time. More hardware, a new headlight bucket (the old one was cracking from age), two side covers to match my NOS Silver/Black gas tank (minus the decals, oh well at least they are black), new cam cover trim and various other bits. This time I used http://www.cheapcycleparts.com/
 
TheCafeKid said:
One thing I DID do what take it apart and put it together with the headers mounted on the bike. Dunno if you are doing that or not, but it made things alot easier. If you're trying to get it together, i would suggest taking a piece of wood that is large enough to cover the whole area of the end of the meg and using the a mallet on that.
Click to expand...

I mounted the headers already, and am now trying to slip the muffler on as you did. I also thought about doing the block of wood thing and using some grease to boot. I just wanted to be sure I wasn't going to destroy the muffler ;)

Thanks bud.
 
Your T spent some time on my wallpaper a couple of years ago. I've been waiting to see what you would do with it. Cheering you on.
 
yasser said:
Your T spent some time on my wallpaper a couple of years ago. I've been waiting to see what you would do with it. Cheering you on.
Click to expand...
:oops:

Thank you bud. I really want to make it look stock. The only problems I see with meeting that goal is the lack of the decals on the covers and the V&H pipe. I can live with that I suppose. :)
 
If ya ever get out this way on her CBM, hit me up! Id love to see her in person!

As an aside, you ever have any electrical probs with your lil 440? I have one sitting here i road the crap out of last summer, and one day, after ridding for a while, i came back out to start her up and NOTHING. i have lights and power, but the starter button does jack squat. I am guessing its something between the start button and the starter, but then i tried to bump start it, and it acted like it wasnt getting spark....
 
TheCafeKid said:
If ya ever get out this way on her CBM, hit me up! Id love to see her in person!

As an aside, you ever have any electrical probs with your lil 440? I have one sitting here i road the crap out of last summer, and one day, after ridding for a while, i came back out to start her up and NOTHING. i have lights and power, but the starter button does jack squat. I am guessing its something between the start button and the starter, but then i tried to bump start it, and it acted like it wasn't getting spark....
Click to expand...

I'd be honored to show you the bike if I am ever up your way.
Could it be the starter solenoid or you mean the engine would spin but not spark? The only common failures I know of on the little KZ's is the ignition.

On another note, the other tire came in today. Next Friday will be a lot of assembling. The cams have to come back out and NOS cam bolts for the hold downs are going in, the stator is getting wired up as well as the regulator, and the new tank/petcock is going on the bike. Actually, I am very excited to see it run again.
 
Well i dunno for sure. It just seemed to get no spark, push starting it wasnt happening, the starter button did nothing. Perhaps the ignitor box took a dump?
 
If the lights came on but the starter button did nothing... It may be the contact within the switch itself. They do have a tendency to corrode on these bike for some reason. If you had no lights or anything, it is the ignition switch plate itself. And if it did turn over, then yep, it is the igniter. Hope this helps.
 
Okay so I wussed out and bought 4 new turn signals from PartsnMore as I posted earlier. Also my other tire came in Friday. Time to put it together. Pics to follow.
 
cloudbreakmd said:
Yasser,
I got part 2 of 2, but not 1 of 2.
Click to expand...

BIG files :shock: - I sent them again today in smaller seperate files. I suspect the first set may be delayed. I may have to break them down by section. They are worth having so let me know if you don't see them and we'll try something different.
 
I hate prior owners...

I hate prior owners...

So I got my parts in today. Along with an extra part I didnt pay for. NOS side covers and an ignition cover.

So I thought I would pull the old ignition cover off and replace it. Yeah...

I look at the cover and there are only 2 screws That's right boys and girls, I said screws. Okay... Fair enough. I soaked them with PB Blaster and used an impact hammer and they came out easy. In fact one seemed to come out too easy. Can we see where this is going?

Upon pulling the cover off, I notice that the gasket is missing. No big deal because I have one. So I put on the gasket and the cover and start tightening the new bolts. First ones goes in, second one sort of goes in and the third one just spins... This sequence of events follows...

:evil: %@)$*@$_*%@%_*%@_%*_*$@$_*@$!!!!!!!!!!

](*,)

:cry:

Sighs. For now I grabbed the trusty locktite and finish reinstalling the cover.
 
continued from above

continued from above

Okay so what do we see wrong with this picture class?

DSCF0706.jpg



DSCF0707.jpg


The last owner must have know he stripped the threads, so instead of just getting a longer bolt, he decided to "modify" the cover to allow a screw to sink closer to the block. I will tap the engine case correctly once she is running.
 
Still working on it...

Still working on it...

No games today. The valve clearances are being checked, new cam hold down bolts, half moon plugs and valve cover gasket in place. New cam cover bolts are next, fully charged gel battery is in place. New NGK spark plugs next. The war is on.
 
Don't worry, the first picture was posed. Cooter here, is my friend and an excellent motorcycle mechanic. He has a GS1100 and owns Brooks Cycle center in Northern Virginia.

DSCF0716.jpg


DSCF0718.jpg


DSCF0717.jpg


DSCF0719.jpg
 
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