Topic: Johnie's 76 GL1000 Sulfur Yellow Build

[Johnie]

First use a meter and make sure it works, before spending time on it. Solder should work too.

I'm thinking of just cleaning up the outside of the case with my Dremel and not dipping it. Playing it safe...

Good news...tested the fuel gauge and needle moves good. Will need to solder that connection back on then clean the tank. Carbs will go on next week. Last hurdle will be cleaning that fuel tank.

Check it first…. I worked on mine and then discovered I needed a replacement!

[Johnie]

Curious to know from you GL1000 guys. How many miles do you get on a full tank of gas?

[Don R]

 Coming back from Sturgis one year I got 140 miles and hadn't hit reserve. I honestly didn't even know if it worked. All highway but 80mph. That was the trip when I was passed by the same 3 Harleys doing 90 and a wife in a chase truck 3 times, then I caught them at a gas stop, the wife shouted holy crap, here he comes again!
 They were curious to know what my mileage was, how fast I was going and how many gallons it held. Their speed required a lot of rest and fuel stops.

[Kelly E]

Coming back from Sturgis one year I got 140 miles and hadn't hit reserve. I honestly didn't even know if it worked. All highway but 80mph. That was the trip when I was passed by the same 3 Harleys doing 90 and a wife in a chase truck 3 times, then I caught them at a gas stop, the wife shouted holy crap, here he comes again!
 They were curious to know what my mileage was, how fast I was going and how many gallons it held. Their speed required a lot of rest and fuel stops.

Speed? Usually Jonesy and I are working our way through the Harley parades passing several pairs at a time.

[Lucien Harpress]

I don't keep track that close with the 1000 (God bless a functioning fuel gauge), but I've definitely get over 120 miles between fill ups, and I rarely use the reserve.  140 sounds realistic too.  Those underseat tanks are deceptively large, especially without any cutouts for a frame backbone like a normal tank.

[Don R]

 I passed a large club of the guys wearing colors that sometimes don't approve of that. I tucked in close behind a truck with a bike trailer on it and didn't look at them. Wooo.

[Johnie]

Coming back from Sturgis one year I got 140 miles and hadn't hit reserve. I honestly didn't even know if it worked. All highway but 80mph. That was the trip when I was passed by the same 3 Harleys doing 90 and a wife in a chase truck 3 times, then I caught them at a gas stop, the wife shouted holy crap, here he comes again!
 They were curious to know what my mileage was, how fast I was going and how many gallons it held. Their speed required a lot of rest and fuel stops.

That's an interesting story Don. Did you get any heat being on a Honda vs HD at the show?

[Don R]

  That's an interesting story Don. Did you get any heat being on a Honda vs HD at the show?
[/quote]

  I went twice but didn't go to the buffalo chip or the other big venues, I stayed with a friend at the Mt. Rushmore KOA and rode with him on a Harley trike once I got there. We did the local rides through the parks, went to Deadwood and Spearfish, we did ride through town, it was the 75th year and there was no place to park. My buddy was new on the trike and freaked out a little. We went past the big campgrounds and kept riding for 40 miles. One day we met a group of my friends and went to the Buffalo jump museum. Everywhere people were cordial and a few guys commented on the "old goldwing".  I went solo to Mt. Rushmore, lead, and up that way.

[Stev-o]

Coming back from Sturgis one year I got 140 miles and hadn't hit reserve. I honestly didn't even know if it worked. All highway but 80mph. That was the trip when I was passed by the same 3 Harleys doing 90 and a wife in a chase truck 3 times, then I caught them at a gas stop, the wife shouted holy crap, here he comes again!
 They were curious to know what my mileage was, how fast I was going and how many gallons it held. Their speed required a lot of rest and fuel stops.

That's an interesting story Don. Did you get any heat being on a Honda vs HD at the show?

Hey Johnie....you never read Seaweb's thread about his epic trip to Sturgis on a CB750?! 
It's a very read when/if you have the time...

http://forums.sohc4.net/index.php/topic,56776.0.html

[Johnie]

Coming back from Sturgis one year I got 140 miles and hadn't hit reserve. I honestly didn't even know if it worked. All highway but 80mph. That was the trip when I was passed by the same 3 Harleys doing 90 and a wife in a chase truck 3 times, then I caught them at a gas stop, the wife shouted holy crap, here he comes again!
 They were curious to know what my mileage was, how fast I was going and how many gallons it held. Their speed required a lot of rest and fuel stops.

That's an interesting story Don. Did you get any heat being on a Honda vs HD at the show?

Thanks stev-o...I will certainly look it up. Sounds very interesting. I've never been there, but some of my HD friends have.

Hey Johnie....you never read Seaweb's thread about his epic trip to Sturgis on a CB750?! 
It's a very read when/if you have the time...

http://forums.sohc4.net/index.php/topic,56776.0.html

[Johnie]

Carbs are done and look real good. I know a retired Honda tech who did them for me. Says these were the dirtiest set he’s ever seen. Glad I had an expert do it. I provided the OEM parts. He used his new sonic cleaner which really did the job.

[MauiK3]

A thing of beauty!!

[Don R]

 On the last two sets I did we used the Randakks plenum seals. I learned not to ignore those things either. I had fuel seeping into the plenum from the internal passages.

[grcamna2]

A thing of beauty!!

Looks ready to go 

[Johnie]

On the last two sets I did we used the Randakks plenum seals. I learned not to ignore those things either. I had fuel seeping into the plenum from the internal passages.

Thanks for that Don...will check it over!

[Lucien Harpress]

Randakk uses viton for the plenum seal, so it doesn't react with ethanol.  His stuff is the best option for these carbs.

Speaking of which, those carbs are a bit like Goldwings in general: a pain to work on, but a thing of beauty once they function correctly.

(I'll keep an eye on this when it comes to your first start.  There is a "fix" to the air idle jets under those side tubes to help with off-idle response compared to stock, but if the bike ends up running fine I wouldn't worry about.  I gotta look up what the details are anyway.)

[Johnie]

Last night I got the carbs back on. Went well. Question for you GL guys...are you able to find the OE braided gas line 5.5mm (pic) or you just using the rubber? If so where are you finding it? Honda rep said the 6.4 hose is fine too. The other issue I am working on is how to get all those wires from the front loom into that rubber OE shield and connect it to the metal band? I have some pics of how it should look, but the PO pulled the stuff out. Maybe I need to heat it up with a hair dryer as it's pretty stiff. Last pic is what I am hoping for on that loom. Guess I could just shove it in there, but I l don't want to have any of the male/female plugs slip out of the connection.

[Lucien Harpress]

https://www.wingovations.com/braidedfuellines

Source for the fuel lines.  The owner is fairly active on the NGW site, and I met him in person about 10 years ago.  A really nice guy, and sells quality products.  I'm running a set on mine right now.  If you do get the braided lines, it helps to seal the ends of the cloth somehow- tape, glue, etc.  I've got heat shrink on mine.  They tend to unravel pretty easily if you don't.

As far as the wire boot- if the rubber is hard, any way you fish the wires through will probably be a struggle.  It may help to electrical tape them together so you're only dealing with one thing instead of a bunch of them.  Heat will probably help too, if only temporarily.

That loop is interesting.  I don't have that on mine- I'll have to look into it.

[BenelliSEI]

Those braided line kits look really nice! I’ve been ordering this 5.5 mm hose on EBay for a while. Just reordered and hope this is the same vendor I used last time. Good quality hose in a Honda wrap. Comes from Japan, free shipping. Usually within a week.

[Johnie]

https://www.wingovations.com/braidedfuellines

Source for the fuel lines.  The owner is fairly active on the NGW site, and I met him in person about 10 years ago.  A really nice guy, and sells quality products.  I'm running a set on mine right now.  If you do get the braided lines, it helps to seal the ends of the cloth somehow- tape, glue, etc.  I've got heat shrink on mine.  They tend to unravel pretty easily if you don't.

As far as the wire boot- if the rubber is hard, any way you fish the wires through will probably be a struggle.  It may help to electrical tape them together so you're only dealing with one thing instead of a bunch of them.  Heat will probably help too, if only temporarily.

That loop is interesting.  I don't have that on mine- I'll have to look into it.

Thanks so much Lucien! I ordered the braided lines from Wingovations and will shrink wrap the ends...good tip. Thanks for the website. And I was able to use some zip ties to secure that harness and get it into the sheath. I used the dealer locator to find the sheath and was told it was the last one in the USA. Moving forward I took the fuel float into a electrical guy to solder the male end on the top of the float. It was pretty delicate work as all that was left was a small ring where the solder contact broke off. I will secure it to the plastic holder with JB to strengthen it. Got my new NGK 5 ohm caps today. Soon will start on the gas tank.

[Johnie]

Got that wire harness sorted. Received the 5 ohm plug caps. No idea why there was 10’s on there. Will snip the plug wire ends and get the new plugs in. Then comes the antifreeze. Got the fuel float repaired and working. Last will be the tank cleaning. Still looking for a left side cover as 1 tab is broke. Not too bad and I probably can put a temporary fix in it place until I can find one.

[Lucien Harpress]

Looking good!  As far as the sidecover goes, how broke is "broke"?  Reason being, yellow bodywork tends to be a bit thin on the ground, and there's quite bit you can do with ABS, ABS cement, and (for really severe cases) a hot wire plastic welder. 

[newday777]

There is a guy in the UK making up replacement pins. He is on fb.

https://mademe.co.uk/shop/ts-3d-printing

[grcamna2]

There is a guy in the UK making up replacement pins. He is on fb.

https://mademe.co.uk/shop/ts-3d-printing

Looks like just what you need to save your side-cover Johnie.

[Johnie]

Here’s some pics of that left side cover. It looks so good I have to save try and save it. I was thinking of bridging the gap and use a zip tie to hold it in place. Of course the broke piece was no where to be found.