General Category > Bike Builds, Rebuilds And Restorations Only
New G5 Project
Antiquar:
I spent the better part of today disassembling the bike.
The teardown was thankfully fairly straightforward. There were a few stubborn bots and rods but nothing that could not be coaxed. The oil from all three housings were clean of metal and each had the right smell. There was moly additive in both the rear drive and gearbox. The PO had overfilled the engine--so easy to do on these bikes.
The rear drives still moves nice and smoothly, I may clean it up and use it without a rebuild. If it does begin to leak it is the easiest component to address. The drive shaft, rear drive, and layshaft splines are in serviceable condition. The u-joint and carrier bearing are in remarkable shape, they somehow feel brand new.
The gearbox was in less admirable shape, and seems to have been leaking, at the very least, from the input shaft. The bellhousing REEKED of gear oil and was quite filthy--mostly on the gearbox side. The clutch pushrod still retains the two conical seals (though installed backwards?). Throwout bearing was in good shape. I will have to replace seals on the gearbox at the very least. I have not opened one of these boxes yet, so that will be new territory to me to reach the shift shaft seal and possibly do shimming.
After some scrubbing it's better, but there's much more to do.
I have yet to disassemble the clutch pack for inspection. I am not hopeful it will be in good condition, especially considering the gearbox leak. Obviously I have yet to inspect the rear main flange or cam plug for leaks. I intend to replace the rear main seal, but should I also replace the flange gasket as a matter of course?
Tomorrow I intend to pull the front end, wiring, and brakes from the frame, along possibly clean more parts.
My favorite bit of wiring I saw today:
azguzzirep:
I loved my G5. Pulled a trailor with it often. The dash lights are terrible. My suggestion would be to go custom with the speedo and warning lights.
Antietam Classic Cycle:
--- Quote from: Antiquar on January 28, 2017, 09:29:26 PM ---The gearbox was in less admirable shape, and seems to have been leaking, at the very least, from the input shaft. The bellhousing REEKED of gear oil and was quite filthy--mostly on the gearbox side. The clutch pushrod still retains the two conical seals (though installed backwards?). Throwout bearing was in good shape. I will have to replace seals on the gearbox at the very least. I have not opened one of these boxes yet, so that will be new territory to me to reach the shift shaft seal and possibly do shimming.
Obviously I have yet to inspect the rear main flange or cam plug for leaks. I intend to replace the rear main seal, but should I also replace the flange gasket as a matter of course?
--- End quote ---
I've had clutch pushrod leaks with the cone seals no matter which way they're oriented. I use a "stack" of six o-rings now and will send you some for free if you'd like, all I'll need is your address.
I would advise replacing the shift return spring while the transmission is open. There are several very helpful tutorials on the five-speed transmission here: http://www.thisoldtractor.com/guzzitech.dk/gb_en_complex-technical.htm
I would replace the rear main bearing flange gasket (seal the threads of the two lower M8 bolts with Hondabond - they're under the oil level and will seep if you don't), rear main bearing seal, JB Weld the cam plug, replace the breather pipe gasket and replace the crush washers on the oil return line (I like to use a coating of Hondabond on them to make sure they don't leak).
Groover:
Congrats! I'll def be enjoying this thread. I succesfully restored an '81 G5 a few years ago with lots of help and support from the members on this board.
Scud:
Great and swift progress. Looking forward to the adventure.
:popcorn:
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