Rebuilding the '80 Wes Cooley

[russr33]

Well I haven't been good at all in keeping up to date on the rebuild, so I'll start now; better late than never. I bought this 1980 GS1000S back in October, a non runner that had been sitting for almost 20 years. Good news was it was low mileage (a little over 11,000) and was in decent shape cosmetically. Bad news was engine was locked up tight and tank was in pretty bad shape. Here's how she was when I got her home:

First thing I did was to get tank cleaned and repaired and seat recovered (seat wasn't really high on the list it just turned out that way).

When I pulled the carbs off, ugh.... (a sign of things to come). Yes that is a pile of rust that came out when I pulled the bowls off! So carbs are absolute junk but the good news was Nessism needed some carb parts for his Cooley rebuild so off they went to him. Also good that the bike came with another set of carbs which were in good shape.

 

[Bribird]

Oh my!!

 

[russr33]

Finally, off with her head! Good gosh what a mess. Again some good news, valves weren't too bad and cams were great.

So in went a 1085 Wiseco kit:

 

[Nessism]

Looking good Russ...and thanks for sending me those old carbs. The parts came in handy.

What's next to do to your bike? Can't wait to see more photos.

 

[Bribird]

Hey Russ, those new pistons sure are purdy!! Nice work!

 

[russr33]

Thanks guys. Glad to be able to help Ed.

I have alot more to show but I'm having touble loading a video to photobucket. Anyone ever do that? Once it links is it the same as linking an image(img code)?

 

[Nessism]

Thanks guys. Glad to be able to help Ed.

I have alot more to show but I'm having touble loading a video to photobucket. Anyone ever do that? Once it links is it the same as linking an image(img code)?

Once the photo is on Photobucket, cut and past the

 

[russr33]

Once the photo is on Photobucket, cut and past the code into the body of your post here and the photo will show up.[/quote]


Right, that's how I post all my pics here. This is actually a video. It says it has uploaded but it doesn't show up?!?! I can't seem to find a seperate section for videos....Read the help section but it says it should show right up. I'm stumped.

 

[Zooks]

Nice work so far Russ. Watching this thread with anticipation, that's for sure.

 

[russr33]

Well the video file I had was too big so no joy there. Just have to take my word for it that she did fire up nicely when everything was back together.


Then it was time to take off all the bits for polishing (all engine covers and fork legs) and order all the parts I would need to make her road-worthy.

Parts ordered included:

Fork seals
Tires (Conti Blitz)
Braided lines
Rear master rebuild kit
530 chain conversion (sprockets and chain)
Progressive fork springs
Engine cover emblems
Front blinkers
Mirrors
Dynajet stage 3
Crankcase breather
float bowl gaskets
Engine gasket kit

All parts were from Z1 and Flatout. I better start winning more at poker to cover my motorcycle habit.....

 

[jwhelan65]

very nice

very nice

Very nice so far Rus, looking forward to seeing this one come to life....Did you pick up Astroman's Kat? smokin deal!

 

[russr33]

Very nice so far Rus, looking forward to seeing this none come to life....Did you pick up Astroman's Kat? smokin deal!

Yep, picked it up today. John was a nice guy and met me half-way in Buffalo, Tx. The bike actually looked a little better than the pics. His buddy did the paint for him and it looks pretty good. Has carb issues, which will be sorted out shortly. All the parts did make it a hell of a deal. I'll start a thread on it soon.

Any chance of you coming up to Austin and meeting us next weekend?

 

[jwhelan65]

Yep, picked it up today. John was a nice guy and met me half-way in Buffalo, Tx. The bike actually looked a little better than the pics. His buddy did the paint for him and it looks pretty good. Has carb issues, which will be sorted out shortly. All the parts did make it a hell of a deal. I'll start a thread on it soon.

Any chance of you coming up to Austin and meeting us next weekend?

Sounds like a plan, but I would have to cage it. I still have my arm in a sling part time. Where are you meeting? Do you live in Texas?

 

[Roadrash]

Very nice can't wait to see more, Nice work !

 

[russr33]

Sounds like a plan, but I would have to cage it. I still have my arm in a sling part time. Where are you meeting? Do you live in Texas?

We're going to be heading that way Friday afternoon. Not sure where we are going to meet. I know we're going to be driving around Lake Travis and the surrounding area.

Yes I'm in Houston. Says so in the right upper corner of this post . You are either in or near San Antonio right? My sister lives on Lake McQueeney.

 

[russr33]

Well I had pics of when all the parts came in and other progress but they are on another camera that's at a friend's house so screw it, on to the good stuff. The covers and fork legs came back from the polisher and as I said the new parts came in and everything went back on and she started to look pretty nice.

Engine cover emblems were obviously different than stock, and that was kind of a bummer but not too big a deal. I'll search for those, but in the mean-time the ones flatout had actually look pretty good.

 

[jwhelan65]

Nice!

Nice!

Looking awesome Rus!..another Cooley saved! great work so far, whats next?

 

[80GS1000]

Wow, very nice! Have you ridden it yet?

I'm putting a replica "S" fairing on my bike soon and need a paint template - would you mind taking a pic of your fairing head-on to see the blue part of the fairing? Kinda like this pic but looking straight at the headlight. Much obliged...!

 

[russr33]

Last was the exhaust. The V&H got sandblasted, then treated to 5 coats of VHT exhaust paint. I had actually bought some of that Techline coating paint and bought a detail paint sprayer, but the fact is I'm going to get some type of new exhaust soon and couldn't justify the close to a hundred dollars for the techline and sprayer. I'll return them unless someone on the forum wants them. The techline is supposed to be great and have a closer to gloss finish. I was quite pleased however with the VHT.

 

[russr33]

Wow, very nice! Have you ridden it yet?

I'm putting a replica "S" fairing on my bike soon and need a paint template - would you mind taking a pic of your fairing head-on to see the blue part of the fairing? Kinda like this pic but looking straight at the headlight. Much obliged...!

Be happy too. I'll PM it to you shortly.