Jennifer's Makeover

[rustybronco]

Eh, nothing to be speechless about. Just trying to make a fairly decent up with what we have. Now if I had new pieces to work with, well that would make both you and I speechless... and broke!

How would you like me to set the odometer's mileage? Current mileage or all zero's?

 

[Flyboy]

Zeros is good, she is zero time hand built from the frame up after all.

 

[Guest]

Pieces parts for the gauge rebuild. Two plus sets of gauges. The plan is to make a set of km/h spec'd gauges. We'll see how that goes after I dissect them.

I'll take the best of what is there, repaint the needles, restore the bracket and fix one broken tab. I just need to find a set of new/good acorn nuts to finish it off properly.

Hey.

I don't see my clock in there!

Daniel

 

[rustybronco]

Hey.

I don't see my clock in there!

Daniel

You will soon enough...

 

[Flyboy]

Correct, Daniel, yours is going to have pride of place on Jennifer and Dale's 850 is going to sport that 140mph clock.

 

[Guest]

Duh.

Reading this. I just remembered that Jennifer involves more than one bike.
(Used parts sure travel a lot. Geographically and bike to bike)

I was totaly forgetting the SA as a GK in MI.

Daniel

 

[rustybronco]

R&R'd the speedo's in Stan's GK to get the 240 km/h so I could use it for Jennifer's guage build up.

A couple of small problems arose.

The first was the difference is background illumination colours between 80 and 84 gauges (I forgot about that).

The second is, I might have to completely gut the 240 Km/h speedo. It appears the needle shaft diameter's are different sizes between the '80 and '84 models, even negating the knurled insert used on the later plastic indicator needles.

More mix and match pieces parts to have fun with.

 

[Guest]

... the difference in background illumination colours between 80 and 84 gauges...
... the needle shaft diameter's are different sizes between the '80 and '84 models, even negating the knurled insert used on the later plastic indicator needles...

I've been on this forum for many years and have witnessed many people take their GS's to bits and analyse the differences between various models but I don't recall anyone going THIS far!

Well done!

 

[rustybronco]

Ivor, glad to see you pop in from time to time.

I have a slight problem. I tend to sometimes take things to the 'nth degree as you can see clearly in the following picture.

In my book there is only one way to do certain things... and that is correctly.

Gauges faces which are of differing colours would eat at me every time I look at them. Wouldn't do it to my own, wouldn't do it to someone else's either.

 

[Flyboy]

Dale, that is a simple enough fix, just use the tacho face off Nancy as well.....but you already knew that.

 

[rustybronco]

Stan, the face that's on Nancy is faded. If I have to I will. Let's see if we can find one before settling on third best.

 

[Flyboy]

Dale, I can't remember, what method do the employ to filter the light to the appropriate colour, is the colour in the face itself removable at all?
If so, it wold be a matter of removing the filter from both faces so they will be white when illuminated and I will install coloured bulbs, which are freely available, even easy enough to make by dipping them in some candy paint.

 

[rustybronco]

The back side of the plastic is a molded on colour. It might be able to be sanded off and resprayed to match the other gauge face. I had thought about doing that as an alternative to replacing the face.

Planing on giving my parts wanted post a week before trying some sort of plan B.

 

[rustybronco]

Stan, as requested...

Spun the speedo with a cordless drill to make sure it worked properly.

Still a lot more that needs to be done, but at least I have the companion gauge face located courtesy of Daniel (Highway_Glider).

 

[Flyboy]

Got back in the garage today, first time since the eye op,
Did not get too much done, although I was in there most of the day.
Fitted the rear brake caliper torque link, fitted the handle bar switches, throttle cable and twist grip. (Thanks Chris)
Spent the rest of the day sanding the clutch cover for polishing, It came out OK, acceptable shine, but I am not happy with it, will hit it again with 1000, 1500, 2000 grit again next weekend.
Like a grumpy old crew chief once said, there is only one way to do it.....right.
While I have the cover off, I will pull the clutch to check the hub nut and measure the clutch springs, also check for grooving of the basket.

Pics next weekend, promise, Ah, what the hell, here is one.

Doc says

 

[Flyboy]

Ok, so I spent quite a bit of time in the garage this weekend, most of it actually, and got a bunch of stuff done, and it starting to show, as I hang more parts back on the bike.

Overhauled, assembled and fitted the front brake calipers.





Also rebuilt and fitted the rear brake caliper.



And rear master cylinder, reservoir and brake pedal shaft thingy





I know, I know, but it was raining all weekend, so painting was out, and I could not fit the master cylinder as it was, so.......
Anyway, had to warm up the polisher for the engine cases.

Redid the clutch cover that I was not happy with, as well as the ignition pick up cover, much better.





While I had the cover off, I checked the clutch condition, happy to report all is like new.
Clutch basket does not have the slightest sign of any grooves.



Clutch plates are also in good nick, so they went back in





The steel plates have very little bluing on them and are all dead straight with no warpage.
The fiber plates are still at 2.9mm thickness, factory spec is 2.9mm - 2.7mm with a service limit of 2.4mm

Clutch spring free length measures 39mm on all of them, factory spec is 39mm - 40.5mm with a service limit of 37.1mm
So all good.

Jennifer is coming together quickly now, and for the first time, I feel like I am turning onto the home straight with the finish line in sight.
She is looking more and more like a complete motorcycle each weekend.

 

[harley10]

So shiny , looking great , when will you think you will have her done!!

 

[Flyboy]

Ok, so for those that don't know and still think that their motor is terminal and wonder where the classic and famous GS "death rumble" comes from, wonder no more....

Click on pic for video

 

[Flyboy]

Thanks Harley, not sure, there will still be a delay or two along the way, due to $$$$, need to buy paint for the tank, and to finish the fairing and front mudguard, that is going to cause a delay.
And of course there will be a bunch of teething problems and little niggles that will need sorting out, you know how it goes.
Also need one or two springs for the mixture screws in the carbs, Lord only knows where I will find those.
I am just praying that when I pull the stator cover off to fit the new one, that the stator is still good. ray:

 

[Nessism]

Stan,

The common clutch basket noise isn't due to lateral play like that, it's because the springs in the backplate are knackered allowing rotational movement between the gear and the basket. Lateral play like you demonstrated should relate to a thrust clearance concern. Maybe look at the thrust washers and such, something may be missing.