New Project

[Stirlingmoz]

Got the gearbox back from Mikey this week.

Thanks Mike - just got do your work justice now.

I’m blown away by the quality of the job - but you guys knew that already.



The missing kickstart gear was sourced from a German specialist - probably will never use it but hey, it’s a G/S so has to have it fitted right

Just need to identify some time to fit it now. It’s probably at least a full day for me - if not two, to install a gearbox and reassemble everything.

 

[Stirlingmoz]

Sometimes you have to go backwards to go forwards.

Stripped a surprising amount off the bike to remove the old empty gearbox case



And with the newly refurbed gearbox in its new home..



That’s all I had time for today but will hopefully get it all back together over Christmas.

 

[Stirlingmoz]

Back in one big bit.

I’m not convinced I’ve got the clutch adjustment quite right though

Despite carefully measuring the 201 - 203mm of cable at the gearbox end, no amount of adjustment will give me any free play at the handlebar lever.

Plenty of time over Christmas to try and figure this out.



Still got the driveshaft to connect up to the gearbox output, grease the swingarm pivots and cable tie some wiring into place.

Anyone know the correct speedometer cable routing ?

 

[mikeyboy]

Is it a new clutch?

 

[mikeyboy]

Speedo cable goes over the air box tubes to LH side,between the main down tubes over the cross brace then straight into rear binnacle housing.

 

[peepingtom]

what a beautiful bike I love it well done that man

 

[Stirlingmoz]

Is it a new clutch?

Thanks Mikey.

The clutch friction plate is new and after a bit of research the issue was rookie error on my part.

I made a 201mm measuring device but measured the clutch arm throw in the wrong place (centre of the cable barrel)

Having read the Tom Cutter method, I did it all again from scratch and it’s working spot on now

The drive shaft is now bolted up to the transmission but I had to walk away from getting the gaiter onto the gearbox collar. It doesn’t want to play and made me say a bad word

I think I may have to remove the silencer and ‘Y’ piece to get better access.

That’s likely a job for next weekend now.

 

[Kenny]

Jack up the swingarm into the horizontal position...will go on 'easily' then !

 

[Stirlingmoz]

Jack up the swingarm into the horizontal position...will go on 'easily' then !

I have removed the shock and done exactly that in my efforts to get the pesky thing on.

I think removing the ‘Y’ piece and getting some assistance (not enough hands) is my next strategy.

This is the last step before filling the transmission system with oil and getting this project to move under its own power for the first time in many years.

 

[Stirlingmoz]

Finished work early today so had another go at getting that rubber gaiter in position.

I removed the exhaust ‘Y’ piece and shock and had the swingarm raised.

And then my pry tool slipped - feck



That’s a new gaiter ruined by my own ineptitude.

Luckily enough I had a spare.

Nothing for it but to strip the whole back end out. Wheel, bevel drive, swingarm, subframe, battery tray etc

With all this out of the way access is much improved and the new gaiter went on easily ‍

Lesson learned.



And here we are on the home stretch.

This is the third time I’ve had the back end apart in recent weeks and I can even remember some of the torque settings.

Once again, it’s all back together - it takes up a lot less room that way.

Just got to fill up the transmission with gear oil now.

 

[Mad Hatter]

It’ll be worth it in the end. Nearly done

 

[Bubb]

On the road for the new year…..great job

 

[Stirlingmoz]

I thought the front brake disc was pretty shot



And managed to persuade a children’s group but from the Siebenrock pre Christmas sale.

We now have this..

 

[Bubb]

Looking great there Pete.
Lovely to see one in the original dunkel Blau colour instead of the far more common white.

Great job resurrecting the old girl.

 

[Stirlingmoz]

The G/S has moved out of the garden room and into the garage so I could fill the transmission up with oil.

I fired it up this morning and I can happily report it moved up and down the driveway under its own power with petrol coming from the actual fuel tank.

@mikeyboy that gearbox shifts beautifully thank you

I’m so happy but it’s not fit for the road just yet.

The front forks haven’t been touched and the brake caliper needs a refresh.

Jobs for 2025

 

[Stirlingmoz]

Elusive part arrived today..




Genuine front fork bridge / brace.

 

[Stirlingmoz]

Work on the G/S has been a bit slow of late.

A lot going at home and at work - you know the story.

However I couldn’t resist this little trinket that I don’t really need - a birthday present to myself.



My plan was to keep the bike stock but I think this was an available accessory so I haven’t gone too far off piste.

Fingers crossed it works as it was a bit of a punt. I pulled the trigger on this one as it was a complete unit - tacho, pod and wiring harness.

Will hopefully have time to fit this weekend

 

[Stirlingmoz]

Little bit of work this morning.

I wanted to fit the rev counter to confirm it was working and connect up the speedometer drive cable.

Here we are with front of the binnacle removed



And then drop the headlight and wiring out of the way - to make access easier..



Just a small tidy of the wiring needed and then re-install everything to ensure it all works

 

[tuftywhite]

I think you'll find it's not a rev counter but a revolution meter.

 

[Stirlingmoz]

Got sidetracked repairing mother in laws fence but back in time to get it all back together.



Next job is to refill the front forks with oil and sort out the front brake.