The rehabilitation of Sir Gustave Sabastian (‘Gus’)

Discussion in 'New Zealand' started by Box'a'bits, Aug 22, 2010.

  1. guzzitony

    guzzitony Guzton

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    Looking good buddy! may even encourage me to get off my arse (or hurry and paint the house..) and do some more stuff on mine. the wheel magnets are sitting at the shop waiting for me as i've got one of those poofy (no offence to poofs intended) digical speedos to fit too............ been sitting in my shed for years so it's not like i'm copying eh?:rofl
  2. Box'a'bits

    Box'a'bits In need of repair

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    Meh.. the standard gauges are part of what I like about your bike.

    Met the former owner of your tank when I needed some machining done. Top guy...
    What sort of pegs did you get?

    The G/S & Basic seats don't fit without subframe modification / swapping. But I do intend to reshape it.
  3. Kokopelli

    Kokopelli Yeah, right!

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  4. Box'a'bits

    Box'a'bits In need of repair

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    They look to run the stock spring?


    PROGRESS UPDATE:
    Spent part of the day tidying the instal & addressing known issues.

    I wondered what the residue was on the front disc after the test ride.. On closer inspection, the disc was brushing the fork protector - I've now cut that back. Melting plastic on your disc is never helpful....:wink:

    Used a hairdryer to take the remains of the 'Yamaha' sticker off the fork protectors.

    Made up a bracket to hold the sensor for the Vapor speedo. This is a much better solution than what I had in the stock forks. We'll see if it performs as well as it should. I'd had issues with the speedo dropping out below 70kph with the past setup.

    [​IMG]

    The brake line I thought I might be able to loop down the forks, ala routing used by some dirt bikes. Unfortunately the line was slightly too short for that, so it is a little exposed. We'll see how it goes. The other routing saw too much brake line looping up into the handlebar area. The brake line will eventually likely be replaced to meet NZ compliance laws.

    The 'seep' that resulted in a drop of brake fluid under the caliper has not reoccurred.

    [​IMG] [​IMG]

    The brake light issue was a wire broken in the (stock) connector. Easy to find, fiddly to fix.

    Still to find a final steering stop solution, but I'm thinking of a bolt up extension to the existing frame mount.

    The puffs of smoke EddieB had noticed at the last ride were concerning me. The bike wasn't really running right for the fork test ride either. The Unifilter is getting a bit dirty, but didn't appear enough to cause this issue (I need to get another 'No Toil' filter oil & cleaner pack). I pulled the spark plugs & right side was fairly sooty. On closer inspection, it turns out the right side choke cable from the under tank splitter was getting hung up, which meant the choke wasn't fully closing on that side. Should be all good now.

    Padmei, can you flick up a couple of photos of your choke pulls? Did you just solder the nipples on some stiff wire?

    Finally, ground a bit off the end of the sidestand, where it was rubbing against the pivot pegs. This was just enough to making an annoying squeaking sound. Not touching now, and the amount ground off is not enough to make any difference to the utility of the stand.

    Ready for another ride now...
  5. Padmei

    Padmei enamoured

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    Bingo with the choke - just got some standard nipples & soldered them - easy. Nice bracket.
  6. Mark_S

    Mark_S Fair Weather Faggot

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    nice work

    why does the axle nut look like its only half on?

    you also may have misread the seal saver installation instructions :)

    fancy a test ride over in the Wararapa sometime soon?
  7. Box'a'bits

    Box'a'bits In need of repair

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    I was checking to see how alert the readers were...:clap Good spotting, you passed the test :clap
    Well where the hell are the damned things supposed to be then?

    Actually just left them there short term while I figure out how much travel I am using. Also checking that the seals are doing their job. I'll slide them down if things get dirty.
    Yup. Keen as. What / where were you thinking?
  8. Padmei

    Padmei enamoured

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    Have you taken your exhaust nuts off yet? I have painted the Y pipe which looks very nice now & was umming & aahing over whether I'd get mine off without rooting them. Since ours are about the same age I think they may be similarly tight. Are they known to break easily?
    I will be using a correct exhaust spanner of course..
  9. Box'a'bits

    Box'a'bits In need of repair

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    I've had my exhaust nuts off a couple of times. I replaced the old ones, because someone hadn't used the right tool, and had bent fins by wacking them with (I assume) a screwdriver & hammer to spin the nuts.

    If yours are frozen (or aren't going to shift easily) and are of unknown age, & maintenance, then you can try:

    1. Heating the nuts (but not the heads), then try the exhaust spanner, or;
    2. Hacksaw the nuts down to near the thread, & then break the nuts open with a cold chisel. Better to lose the nut, than damage the head exhaust thread (spendy to repair).

    I can lend you my old exhaust nuts off my bike, if you need them.

    If the threads should happen to get rooted, then there is an alternative to repair here

    Make sure when you put them back on that you use a high temp moly grease in the threads (I used to use Copperslip, but I'm now told that this promotes corrosion between the threads, not prevents it....)

    Um...& hopefully I'm not going to regret this, but what colour did the Y pipe turn out? Red?
  10. Padmei

    Padmei enamoured

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    I may wait & get some spare nuts incase I root mine getting them off then.
    You'll be pleased to know the pipe is a low gloss black - spectacularly pedestrian:D

    My word I nearly fell over when I saw the price of those alternative exhaust nuts - gonna have to sit down for a while
  11. Mark_S

    Mark_S Fair Weather Faggot

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    Maybe Sutherlands Hut or something similar - provided we can find a nice day - maybe this weekend?
  12. Box'a'bits

    Box'a'bits In need of repair

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    :clap
    Still likely cheaper than getting someone to machine up new threads for the head.
    Likely Saturday then. Forecast says that this will be the best of the weekend.
  13. Box'a'bits

    Box'a'bits In need of repair

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    Doesn't look like Saturday after all, 'cause the weather is supposed to be variable. What about Sunday?


    LIST OF MODIFICATIONS, REPLACEMENT PARTS ETC
    A friend asked me that most dangerous of questions the other day. 'What on your bike is non oem new parts, modified stock parts, & renewed stock parts'. That had me thinking, so I thought I'd record it now. I won't total up all the costs, & no, I could not sell the bike for what I have invested in it.

    Starting at the front (updated 21/11/12):

    Aftermarket / non BMW:
    - YZ250F front end, ie triple clamps, forks, axle, & front hub. The forks have been shortened initially to 225mm travel, now 250mm. The springs have been cut by 75mm, (but I've now put in a 25 mm spacer in order to make up for some of the shortening). New flat ends made on the springs. New bushes & seals throughout (several times :lol3). The steering stem has been modified with a 20mm spacer & sleeve to fit the BMW headstock;
    - Excel Takasago Front Rim (The YZ250F OEM DID got a little square;
    - EBC Supermoto 320mm brake rotor, adapter, & YZ250 brake caliper, running a stainless braided brake line
    - Rok Risers
    - Initially Pro Taper 'Raptor' bars, now Sunline CRF bars
    - Barkbusters
    - Oxford heated grips. Wiring to include a relay to allow these to go off when the ignition is switched off
    - Baja designs 8" race light. The light reflector has been replaced with a Hella semisealed unit, using a Boatmans H4 conversion ring. The light is running a 90/130 H4 bulb, & 20w halogen pilot bulb, all run off relays & upgraded wiring
    - KTM indicators (front & rear)
    - Homemade indicator / speedo mount / ignition mount
    - Vapor Speedo, with the additional idiot light panel. Filament bulbs switched to LEDs
    - HPN tank
    - Hardhead valve cover protectors
    - Enduralast Alternator
    - Ohlins rear shock
    - Touratech bag mounts
    - Uni Filter air cleaner
    - Gearbox oil sight glass
    - HPN oil cooler thermostat
    - Pivot pegs
    - PD Baseplate (replaced the prior owner home made item)
    - Keihan 38mm headers, Cycleworks made Y Pipe & link to an SV 1000 Muffler. Previously stock headers coupled to a stainless collector box made by the prior owner, & stock muffler. Experimented with a Keihan 2 into 2 - but I could not recommend that.
    - Replacement LED Tail Light insert

    - Touratech Zega Hard Panniers SOLD
    - Tokico 4 pot caliper conversion (ex RGV250), with alloy adapter link & custom stainless brake line - SOLD

    Stock modified:
    - Roobars, & fairing removed
    - Wiring loom shortened
    - Seat modified to fit the HPN tank
    - Oil cooler relocated from the crashbar to the centre of the frame
    - Rear brake lever modified to improve leverage
    - Increasing the wading depth of a Paralever GS (float breather mod)
    - Rebuilt gearbox with circlip mod & repairs drain plug part one, part two, part three, part four, part five

    Stock renewed:
    - Clutch. Replaced pressure plates, friction plate etc
    - Clutch pushrod bush
    - Carb jets, seals etc, as well as carb top stainless allen screws, choke & throttle cables etc
    - Swingarm paralever pivot bearings & pivot
    - Gearbox output seal
    - 9.5:1 pistons fitted, & re-ringed
  14. Mark_S

    Mark_S Fair Weather Faggot

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    fook fook fook
    last night someone turned a tap on in my nose and stuck a knife down my throat
    unless I improve a lot today I won't be riding this weekend. :cry
  15. igormortis

    igormortis Cafe Reise

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    Not to be an alarmist, but be careful with ‘flu like symptoms at the moment. I’ve just had to have checks done due to measles exposure. :puke1
  16. gsd4me

    gsd4me 90% bluff

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    Have been perusing `olds cool`, clicked on a link and discovered this thread. As I intend to return to the airhead fold in the near future, I`ve been keen to read anything about GS specials.

    I used to visit the NZ forum daily, but since MarkS stopped posting regularly I haven`t been here so much; now I have a reason.
  17. Mark_S

    Mark_S Fair Weather Faggot

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    I thought my thread was getting a bit 'ground hog dayish'

    I posted a few photos from last weekend's ride for your entertainment
  18. Box'a'bits

    Box'a'bits In need of repair

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    One of my favourite movies

    See, I told you that you needed my bike issues to add spice....:evil
    Thanks for your interest David. I'm enjoying evolving this bike
  19. Mark_S

    Mark_S Fair Weather Faggot

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    so - did you get out for a ride?

    I stayed at home feeling sorry for myself.....
  20. Box'a'bits

    Box'a'bits In need of repair

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    Yup, took Mandy for a ride to Raumati. Would have called in but I left my phone at home, & I haven't actually been to your place yet...:wink: Had a nice lunch & coffee at Valhalla on Renown Rd.