Strip & Re-build

[929bladerunner]

I was just wondering if anybody has posted a blow by blow account of how to strip down (for frame powder coat etc) and then re-building a old airhead (preferably GS) or is it a case of common sense and a Haynes destruction manual ?

 

[(RIP) pastyman]

Pretty straightforward really. Ive done my 100gs and now doing a partial job on the 80g/s. Like a mechano kit really. All the nuts and bolts came undone and could be reused. Whole rear subframe comes off as one. Swing arm together with diff etc as another. then it was gearbox, and then engine after removing top and starter. I didnt take the forks out as I decided to go down the Smoothrite road rather than powder coating,(there has been much on this already, but in short you can touch up paint whereas powder coating chips and harbours water underneath without you knowing about it)
All of the dismantling can be done in a day. IMHO you cant get a better bike to do this sort of job on..

 

[Wanderer]

1. Digital camera - take pictures of everything
2. Note book - make lots of notes
3. Clymer manual
4. Methodical approach
5. Maintain orderly work area

Enjoy!

 

[bakerlonglegs]

1. Digital camera - take pictures of everything
2. Note book - make lots of notes
3. Clymer manual
4. Methodical approach
5. Maintain orderly work area

Enjoy!

Take LOTS of pictures as you take the bike apart.

I stripped down and rebuilt a G/S last summer, my first project. I wasn't so lucky with fixings - most were rusted-on scrap - but other than that it was fairly easy and a Clymer manual is a worthwhile investment. I did get stuck on a couple of things - and got lots of help on here before I did too much damage .

 

[Rob Farmer]

I did get stuck on a couple of things - and got lots of help on here before I did too much damage .

929baderunner,

Lovely things to work on and very rewarding to rebuild.

I'm not too far away and have done a few airhead rebuilds, if you want to borrow some kit or bring something over for a rebuild just drop me a line

 

[Bomber]

Rob , what a ' kind offer ' I am just loading the R80/7 ,R100 GS and the Desert Storm bike into a van to drop off to you for a rebuild.
Hope thats OK ?

Thanks Bomber.

I know I express my feelings openly when I am unhappy with some thing but it is when you see people like you making offers like this that it reminds you what the Forum is all about !!!

In all seriousness I have a number of projects you could be interested in !!

Bomber

 

[Tarka]

or is it a case of common sense

That bit.

and a Haynes destruction manual ?

With a bit of that.



Anyone needing a step by step illustrated guide on how to strip and rebuild such a basic machine for the likes of frame powder coating shouldn`t be doing it.

 

[929bladerunner]

Thanks guys for the (mostly positive) replies, especially Rob for your kind offer should I need some help.

 

[ChasF]

Anyone needing a step by step illustrated guide on how to strip and rebuild such a basic machine for the likes of frame powder coating shouldn`t be doing it.

I've often wanted to say the same sort of thing to the endless list of people who want to rewire their house or fit a new bathroom and ask me how to do it. If you haven't got a clue don't even start but with a little applied common sense it couldn't be much easier than an Airhead. Take photos of the electrics and leave as much connected as you can.

 

[(RIP) Bin Ridin]

I think Tarka is fishing (Otter, gettit?), tongue-in-cheek.

Nothing better than a good job like that. I'd say a clean warm dry workshop is the most important thing. The know-how comes when needed, hopefully.

Bin

 

[(RIP) pastyman]

I know Ive replied once already on this, I agree with some of the other comments and can only add that you must assemble all the appropriate tools. Ive included a pic or two of my rebuild on Bertha. ( appologies to those who have seen them before

 

[(RIP) pastyman]

Shes not bad now though

 

[Redboots]

Shes not bad now though

Can you tell me where the headlight & bar came from... Please.
Trying to find something to replace the horrid square jobbie.

Cheers,
John

 

[929bladerunner]

Cheers for the pics - the finished bike looks very nice. What did you strip her down for - just to tidy up and re-paint (Smoothrite) frame etc. or did you have some mechanical work to do that required the engine out?
Also, do the cylinders need to come off in order to remove engine, or does it just make it easier/lighter to shift ?

Cheers,
Stu

 

[Flipfly]

Cheers for the pics - the finished bike looks very nice. What did you strip her down for - just to tidy up and re-paint (Smoothrite) frame etc. or did you have some mechanical work to do that required the engine out?
Also, do the cylinders need to come off in order to remove engine, or does it just make it easier/lighter to shift ?

Cheers,
Stu

He did it because there aren't many nightclubs where he lives

It was looking a bit tired. Looks really good now, but not a patch on his new project

The Dak in the background now resides in Stoke on Trent and I need to change my signature............figure it out

 

[(RIP) pastyman]

Can you tell me where the headlight & bar came from... Please.
Trying to find something to replace the horrid square jobbie.

Cheers,
John

Hi Redboots, I got the bike like this but there was some discussion on this site quite a while ago about the lights, It seems that they are off a Honda Baja (250) trail bike. Someone posted a pic of it and it does look identical.Must say the lights are fine but it does expose the back of the clocks to the weather. I fitted a plastic lens protector over the front more for weather protection. Tony

 

[(RIP) pastyman]

Cheers for the pics - the finished bike looks very nice. What did you strip her down for - just to tidy up and re-paint (Smoothrite) frame etc. or did you have some mechanical work to do that required the engine out?
Also, do the cylinders need to come off in order to remove engine, or does it just make it easier/lighter to shift ?

Cheers,
Stu

Hi, Bit of both really. She was pretty tidy when I got her but has done 93000 miles. As flipfly,Mrs Flip and Syco and I were planning a trip to southern Spain, I wanted to check everything out including the rear suspension(paralever) I had also decided that as she was burning a bit of oil I should do the valve guides hence the cylinders off. I suppose its a bit lighter to get out with them off but it can be done relatively easily with them on, You have to tilt the engine to the right for it to come out. In the end I replaced all the bearings in the swing arm, new valves and guides, camchain, piston rings and all sorts of bits and pieces as well as checking other parts and painting those bits that were a bit tatty. In the end though she let me down in France due to a simple oil leak in the filter( read "the $2000 oil seal" on the airheads web site) completely destroyed the bottom end. All fixed now and running great

 

[(RIP) pastyman]

He did it because there aren't many nightclubs where he lives

It was looking a bit tired. Looks really good now, but not a patch on his new project

The Dak in the background now resides in Stoke on Trent and I need to change my signature............figure it out

Whats a night club???? Can people go out after dark?? What about their ovaltines.

 

[Redboots]

It seems that they are off a Honda Baja (250) trail bike.

Thanks Tony. Might just take a look around for some

John