New GS, engine seized. Diary of Rebuild/Testing - LOTS OF PICS!!!!!

[morbidelli17]

I just spend 45 minutes reading this whole thread.

Awesome.

You'd BETTER get this thing running.

[yamahonkawazuki]

indeed

[utgunslinger13]

Thanks for all the kind words guys, hopefully this weekend I'll be able to strip it down and do a final weld and sand on anything remaining.  Once thats to my liking, the frame is going to be sent out to either get painted or powdercoated.  While the frame is out, I'm going to get the engine back together and hopefully have it ready when the frame is completed.

Partial list of things still to do:

~Finish Frame and side covers to cover the new openings
~Powdercoat/Paint parts (wheels, frame, etc)
~Reassemble Engine
~Find a suitable mud shield
~Reroute all wiring to match new tail section and placement of relays etc.
~Tank will need to be gone over to remove any rust and coated then repainted
~Still undecided on sticking with stock gauges or going digital
~Replace headlight, still undecided on what to replace it with

[Jay_wolf]

If your getting the frame welded , why not just have a r1 tail welded on and powdercoated , with a katana Wheel .. mhm yum

[utgunslinger13]

If your getting the frame welded , why not just have a r1 tail welded on and powdercoated , with a katana Wheel .. mhm yum

Because I'm welding the frame and I like the Buell X1 tail section better 

[utgunslinger13]

So I started tearing everything down for the final prep before sending it out for powdercoating or paint.

Here is the frame waiting for its final sanding and welding, still need to remove the kick stand and center stand, and a couple bolts.  This will all be painted or powder coated Charcoal:




Here is the rear swing arm, still need to disasemble it.  Everything except the rotor, caliper, the stabilizing bar, and chrome piece above the foot peg will be painted or powder coated Charcoal:




Here is the front forks, which still need to be disassembled.  The rim will be powder coated. The only thing being painted on this is the front fender, both painted and black portions:




Here is a bunch of random parts that will need some attention later.  Carbs will probably need to be cleaned and rebuilt, tank will be repainted or powdercoated, and headlight will probably be replaced:




Here is the absolute mess that is known as the wiring harness, the idiot before me jacked up so much of the wiring I'm actually contemplating replacing with a new harness to save the work of rebuilding it.  Things are so mess up, I can't completely seperate the harness from the headlight bucket or gauges without cutting wires!:




Here is a close-up of the mess with the harness inside the headlight bucket:





Thats all I have for now, will keep it updated as I progress!

Thanks,

Nick

[Jay_wolf]

Nice

[Jay_wolf]

If you Havent Already , get a katana back wheel and have it powdercoated , then u can have a 150, or 160 . and even a 170

[utgunslinger13]

Jay_wolf:

Right now I'm sticking with stock everything except the tail section, getting it back together and running then I will start thinking about mods later.


Not much of an update, but last night I was able to break down almost everything in the rear swingarm and get it seperated to start looking at what will need to be powder coated or painted.  I did hear back from the local powder coating place and they are looking at 300 for 1 color (frame and other bits I want the same charcoal color), 365 for frame and other bits charcoal and the tank a 2nd color, and around 425 if I want to do frame and bits charcoal, tank another color, and suspension black.  I'm starting to think a rattle can job might be the best option as I don't think I should spend that type of cash on the powder coat as I bought the bike for less!


Anyways, here is a picture of the suspension parts I was thinking should be black.  I was also looking at matching the shock to the blue I want the tank:





Here is the swingarm and rear rim that will be Charcoal to match the frame, and the brake caliper and brace that will be repainted black:






Tonight I'm hoping to get the front end tore down and picking up some paint to start the painting process!

Thanks,

Nick

[Jay_wolf]

then u have to get the wheel painted or powder coated again , the fact the wheel is cheap as chips ,

and i look at the stock wheel on mine , looks so bad , i  have a kat wheel , just need a break disc and have it mounted, they fill out the rear


u need a wider rim with the x1 tail , jim had a 180  then a 200

[utgunslinger13]

Yeah eventually I will probably end up getting the bigger rear rim but thats not high on my list of things to do right now.  I'm not that worried about filling the rear end up right now.  I'm sure once I get it back together and start riding, I'll notice the difference but for now I'm keeping it stock.

[utgunslinger13]

So i finished the tear down last night and now have all the parts seperated that will need paint.  I did decide that I don't want to spend $400 on powder coating so I will be cleaning the parts this weekend, and I'm hoping to get my first spray down and possibly finish the frame!

Here is the two rims, swing arm and extra bits all broken down.  These will all be getting sprayed Charcoal.  In the upper portion of the picture you can see suspension bits, those will be painted black and I'm thinking of painting the spring to match the tank's new color (still undecided at this point):




Here are the two forks which will be going Charcoal, and a bunch of other parts that are not getting any paint:



Thanks,

Nick

[notjohndavid]

I thought way back when... you started the engine work that you "didn't have a place to work" lol

[utgunslinger13]

I thought way back when... you started the engine work that you "didn't have a place to work" lol

Yeah I did, but if you read back to page 10, I moved into another apartment and this one has a garage!  So now I have a good bit of room to work on the bike.

[Roshan]

4.24 am. Read through all 14 pages and just wanted to give u wraps on staying focused on the project. I hope you get the bike up and running soon and can't wait to see some more pics after the paint job.

keep up the good work!

-Roshan

[cantseejack]

I signed up just to say that this is awesome.

[utgunslinger13]

Thank you for all the kind words.  Its progressing much slower than I would like but it'll get there eventually!  Here are some pics of what got done over the weekend.

I got the rims painted and just sitting in the garage curing right now, should be able to clear coat them this weekend:





I also picked up some more welding wire to finish welding the frame.  Got it welded and primered:




I have almost everything primered (except the entire frame) and a few other bits painted black.  The suspension parts are going to be charcoal:




Here is the one fork (still trying to get the caliper disconnected from the other fork) and the swingarm that needs some more cleaning before I finish painting it:





I probably won't have as much time to work on it this weekend as we are going on a company camping trip Friday (great excuse to miss work!) and won't be back till late Saturday.  But hopefully I'll get some more paint down since most everything is downhill from now on.  As always I will take pics and keep you updated!

Thanks,

Nick

[DoD#i]

For future reference, take the caliper off before taking the fork out of the triple. Taking it off before you take the wheel out is not strictly needed, but makes that a whole lot easier, too.

I used something like a short chunk of 2x4 to give the 8mm Allen wrench a smack to get those caliper mounting bolts started coming off. A relatively gentle impact.

[qwertydude]

Adding to this impossibly long post. Is that a king's rear tire? It could be a Dunlop GT501 which the kings is a clone of, but if it's kings 140/70-17 then yay! Someone else with this cheapo tire. Not the greatest but is good for it's 50-60 dollar price tag, and long lasting 10,000 miles on my last one. Hard to mount and took 3 ounces to balance but hey can't beat the price 

[pronator]

I'm not sure from the pic but it looks like you painted primer on the entire rear shock? I don't know much about suspension but I don't think the chrome bar on that shock is supposed to be painted. Just a heads up. 

The rebuild looks like it's coming along really well though. Great job!