The 2,298 Mile Wes Cooley

[jwhelan65]

Hey Joe,

I don't have an end plan for this bike............ I really enjoyed the last Cooley project and I certainly didn't do it with the intent to sell.

I just had the sense the timing was right and it was. The new owner was thrilled and I hope is still enjoying the bike (ratty Yoshi excluded).

With that said, I do seem to have the tendency to enjoy something for a bit and then move on to something else.

However, this bike just seems special. The chase was interesting, with lots of help along the way and the story behind the bike is somewhat cool!

The nice thing about the Cooley is the following. It's a bike that commands a price high enough to keep them in caring hands.

I could not agree more, they are golden. My hunt continues for the right bike. I have had a build list going on for a couple of years for one of these things. I luv the stock look but my spider senses tell me a non-invasive, reversible, period correct, lightly modified build would happen if I get ahold of one.

Great job on your second go around, its always a thrill to see your steady attention to detail as it progresses.

 

[nvr2old]

I agree you guys. That was what I wanted with mine, also. Slightly modded with era correct changes that wouldn't affect or change what's so special about the S to begin with.

 

[Vmass]

Finally got a little time to continue the breakdown. Pulled the carbs and everything seemed to move freely.

Unlike my 1980, these carb boot screws came off with a simple twist. I remember having to use and impact driver and was expecting the same. O-rings were in good shape.

Very clean inside the intake port. I did notice the inner edge of the port looks like it was beveled ad I don't recall seeing this on the 80'.

 

[Vmass]

Valve Clearance Check

Valve Clearance Check

I was happy to get a little garage time today and did a check of the valve clearances. Here is what I found:

Exhaust

1) .051/2.80
2) .076/2.75
3) .076/2.75
4) .076/2.75

Intake

1) <.038/2.80
2) .051/2.80
3) .063/2.75
4) <.038/2.75

I am not sure if others add or subtract rom the feeler gauge measurements, depending on how tight the fit is.

Intake #1 and #4 would not take the smallest feeler. However, the shims and buckets would spin freely.

Should I order a couple 2.70's and 2.65's?

Here is a couple pictures of the cams and chain......looking very young!

 

[Nessism]

Looks like you need one 2.70. Pretty sure I have a spare so PM me if you want it. Doubtful to be needed on anything other than a super low mileage engine.

Interesting that the cam sprocket has that resin cushion shoulder for the chain. Pretty sure Suzuki stopped doing those in 1980, for the 1000 anyway. The resin would sometimes crack and separate, so keep an eye on that.

 

[Vmass]

Thanks Ed,

If I am looking at it correctly, I will need to go down at least one size for intake 1 and 4. So I should start with a 2.75 for 1 and a 2.70 for 2, yes?

 

[gs58]

The rubber between the dashboard and the fairing is different to mine. Mine has short U shaped pieces that cover the edge of the dash. Which is original?

Nice find by the way. I'm sure that there are a lot of envious people out there (me included). IMO what you do with the headers and carbs depends how much you are going to ride it. And it would be (IMO) a real shame to put many more miles on this bike. I'd be tempted to restore to original specs and park it in my lounge.

 

[gs58]

I'm not so sure that it is a Yoshumira pipe. All the ones that I have seen have a constant curve with a inconsistant radius from the head to the collector. That is no straight lines in line with the frame down tubes.

Like this;

http://www.youtube.com/watch?v=v8mMQbEkr8w

 

[Vmass]

The rubber between the dashboard and the fairing is different to mine. Mine has short U shaped pieces that cover the edge of the dash. Which is original?

Nice find by the way. I'm sure that there are a lot of envious people out there (me included). IMO what you do with the headers and carbs depends how much you are going to ride it. And it would be (IMO) a real shame to put many more miles on this bike. I'd be tempted to restore to original specs and park it in my lounge.

Hey gs58,

I believe the U shaped rubber pieces you mention are what is underneath the rubber trim you see on mine. I would say that you are simply missing that rubber gasket you see in the pictures above.

I am not sure of the level of restoration I will do on this bike. I am going to start with basic maintenance and see how it runs. Then I will decide on what to do with it. I don't expect any issues with the mechanics, as the miles are low and everything seems original, with the exception of the Yoshi pipe and main jets.

 

[Nessism]

Thanks Ed,

If I am looking at it correctly, I will need to go down at least one size for intake 1 and 4. So I should start with a 2.75 for 1 and a 2.70 for 2, yes?

My post was messed up Rich. You need one 2.70. Move 4I to 1I, and get a 2.70 for 4I.

 

[Vmass]

My post was messed up Rich. You need one 2.70. Move 4I to 1I, and get a 2.70 for 4I.

Looks like that will do it....thanks.

 

[Kiwi Canuck]

Rich, If you can wait a week or so, I'll throw in a 270 in the package I'm sending as I'm sure I have a few spares of that size.

Cheers,

David

 

[Vmass]

David,

I appreciate the offer. I have a PM out to the shim club to see how it works.

If you find you have a spare 2.70, that will be great. If I don't use it, I will get it back to you.

Thanks very much!

 

[Kiwi Canuck]

David,

I appreciate the offer. I have a PM out to the shim club to see how it works.

If you find you have a spare 2.70, that will be great. If I don't use it, I will get it back to you.

Thanks very much!

I used the shim club a few months ago, I purchased 5 or 6 shims rather than mailing in my old ones and having them exchanged.
About $6.00 each IIRC.
My dealer here charges about $12.00 each plus taxes which I paid when I needed some right away.
I have 2 spare 2.70's, I will put one in the package.

 

[Vmass]

All good with valve clearances and shims! Was headed home and my route took me past a Suzuki dealer.............2.70 shim= 4 bucks!.....done. I will do the swap and move on.

Thanks for the shim offer, Dave and Ray.

And thanks for your help, Ed.

 

[Kiwi Canuck]

All good with valve clearances and shims! Was headed home and my route took me past a Suzuki dealer.............2.70 shim= 4 bucks!.....done. I will do the swap and move on.

Thanks for the shim offer, Dave and Ray.

And thanks for your help, Ed.

That's awesome, $4 that's a deal.

BTW the inside of the engine is just dazzling, haven't seen one like that in a long time, good to see it's better than expected .

Cheers,

 

[Vmass]

It's been a while since I put some time in to the bike. Today I put the valve cover back on.

Pulled the oil pan............ very clean, no metal shavings of any kind. A little sludge at the bottom. Must be residual from it's second oil change!

Most of the oil pan gasket stayed on the engine. Not a lot of fun scraping the gasket off. I am hopeful it is clean enough for a good seal. Installed oil pan with new OEM gasket.

It was in the 50's here today, so once the above was complete, I rolled it off the lift and did a good simple green cleaning and spray down.

The carbs are done, with the exception of a little detailing. I have a stock air box that I started cleaning today. Not sure it is going to be a good candidate.......... the breather connector is snapped and barely attached and the box itself is somewhat concaved in the center near boots 2 and 3. I put the carbs up against the boots and it is off quite a bit. We will see how that goes.

I think I may move towards firing it up, before I stat brakes, fork seals etc.

 

[Vmass]

Well, I am really behind on this project. It's been a busy, cold winter. My plan was to dedicate this weekend to the Cooley. Not sure it will get the whole weekend, but I did get a few thins accomplished!

The rear of the bike is pretty clean. MC and caliper rebuilt with new Apex line. New rear wheel bearings and an Avon Road Rider tire.

New 630 chain (need to by a chain tool for link or watch a youtbe video), original sprockets are in fine shape.

Before:


After:










My goal is to just clean it up and do the required maintenance. Still haven't decided on what to do with the painted parts. Maybe I will run it this year with the original paint.

 

[Vmass]

 

[Kiwi Canuck]

Chain Tool

Chain Tool

Well, I am really behind on this project. It's been a busy, cold winter. My plan was to dedicate this weekend to the Cooley. Not sure it will get the whole weekend, but I did get a few thins accomplished!

New 630 chain (need to by a chain tool for link or watch a youtbe video), original sprockets are in fine shape.

.

Rich, good to see you getting some work done on the bike, I've been slacking off a bit on the bikes the last month myself, need some good spring weather to get me motivated.

If you purchased the chain with the rivet link, the chain tool is not quite strong enough to rivet the pins.

I used a chain tool to assemble the links but needed to use a mini sledge behind the chain and a ball peen hammer to rivet the pins.

See my rebuild thread on the topic.

http://www.thegsresources.com/_forum/showthread.php?t=209217&page=7
Starting at post #251

Bike looks great BTW.