1980 GL1100 "Orange Crush" build

LOL I rode mine from NB to WV with the timing way off 2500 miles. Didn't know it until I did the Randakk's split timing method and everything worked better and the bike went from cranky below 3k to alright above 3k to smooth idle and a rocket after 3k all the way to redline. The new points and correct timing made a huge diff and I now know when the bike isn't running tip top. So when I have time I need to check valces and timing to get her set back right.
 
CARB DAY!

The original carbs off Orange Crush, albeit dirty, were in great shape mechanically. No play on any of the shafts. No evidence of leaks in the past. Mechanically, everything is really tight and new feeling.

So For now it was just a good cleaning and new manifold gaskets.

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left half is after a simple soak and scrub, right half is untouched.

After a full hour of scrubbing in the parts cleaner, and then a good spray down with ZEP Industrial parts cleaner, and pressure washing heres the result...
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The bowls on top got a simple cleaning to get the old paint off, and then a rough red scotch brite session gave it that brushed look.
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These are going to go on for now if they leak slightly or not. i can do the rebuild on the carbs from the donor bike and swap them after the bike is assembled and all the gremlins are worked out.

Also got the Rear brake Master torn apart. Figured out when it was no workie, all clogged up from disintegrating flex line. Will post pics of the cleaning process tomorrow. Then it's reassembly, and install of the rear brake master, plumbing of flex lines, final hook up of the rear brake pedal. After that it's rear wheel assembly and install, rear suspension install, and then onto rebuilding of the rear caliper and install of that as well. I'll be a busy boy this weekend.
 
Today: rear master rebuild and install....

At the shop, got the master apart, blasted the outside of the housing, cleaned out the inside and lubed with brake fluid. Blasted the op-rod, and readied for assembly.
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All Assembled, the was the original unit off the bike 1st bike. Action is nice and smooth, no hangups.
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Came home and removed the front fairing off the donor bike. If anyone local to the SF bay area wants it, come get it. Otherwise, it's going in the trash on tuesday.
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Got the brake line hooked up and routed and master bolted in place and connected to brake pedal. Again, action is nice and smooth. As smooth as my 2010 VT1300CS actually.
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Reservoir all installed and bolted down.
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And side cover snaped back on for the night.
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Tomorrow i'm assembling the spare rear wheel and install and possibly pulling the front wheel off the donor bike. Orange Crush will be off the stand tomorrow evening!
 
Radiator, rear suspension, rear wheel oh my!

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I'm extremely pleased with how the seat looks now that the temporary rear wheel is on. kinda squatty looking. I'm really liking it.

Tomorrow, front wheel prep and paint. Gonna order throttle cables, choke cable, carb manifold gaskets etc....
 
downtown809 said:
The seat looks great, where did it come from?
Click to expand...

Ebay. It's built to be for a CB750. The guy makes them in his garage. He gave all the dimension of the seat and I measured it up to the frame and it matched up perfectly. I was really impressed when it arrived. No pinholes, all the edges were really nice and smooth. Didn't have to do any bodywork besides sand, prime and paint.
 
Over the last few days I've been getting the front wheel ready. Chemical strip and blasted it. Hand scuffed and then shot the whole wheel with satin black wheel paint. Then hand sanded all the edges like Comstars are supposed to be. Took the wheel down to the local cycle salvage and had them mount a new tire and install new wheel bearings before balancing. Will take pics when she arrives back home tomorrow.

Side note. Throttle cables, clutch cable, choke cable, hand grips have been ordered.

-Matt
 
Maritime said:
This is going to be a beauty when you get her finished.
Click to expand...

Thanks man. Wait till you guys see what I have planned for the front fender. As the things get's closer and closer to being able to fire it for the first time in over a year, i'm getting more and more nervous that i fucked something up along the way. A few more weeks and we'll see.
 
Front wheel is done, need to scrub the speedo drive, btu other then that, wheel has been restored, new tire and new all balls wheels bearings. Gonna install and get the bike on the ground on Sunday! Oh yea, new choke cable arrived. Gonna blast the bracket and trim black it at work tomorrow. As soon as manifold gaskets show up the carbs go on.

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side question. What does the axle nut that holds the speedo drive to the wheel need to be torqued to?

-Matt
 
SHE"S ON DA GROUND!

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Pulled the front rotors off the donor bike as they were drilled and have plenty of life left in them.

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Front wheel all bolted up.

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One of the new handgrips installed.

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carbs and choke cable installed. Choke cable bracket is at work. Will finish painting it and install tomorrow.

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left hand control installed. And I just realized that both the control and grip will have to come off to get the clutch lever on.... doh!

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Fuel lines run....

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At then end of the night...
 
ront caliper brackets, blasted, painted and installed.

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Getting them installed was tricky. having to adjust the spacing left to right..... ahhhh, finally got it all set.

Clutch lever is all blasted, cleaned up, and reassembled.

Will get the whole left side of the bars all assembled. Speedo cable has been ordered, gonna pull the tach cable off the donor bike.

Sunday I'm gonna try to get the front calipers installed, lines run, and gonna order the upgraded front master from Randakk this weekend. Also gonna get the shifter lever installed, and try cranking it over this weekend.

Finger crossed everything works out okay.
 
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