Yamaha GTS 1000 - Recommission
A customer asked us to look over his motorcycle, with a view to putting it back on the road. He informed us that it was a 1996 Yamaha GTS 1000 that hadn’t been on the road for 12 years. As our mechanics are motorcycle enthusiasts, we were more than happy to take the project on. The GTS 1000 was a bike ahead of its time due to the forkless front suspension, electronic fuel injection, and ABS braking system. In 1996 these features were uncommon on motorcycles.
We went to collect the motorcycle and found the bike stored in a garage. Although it was heavily covered in dust, initial thoughts were that the bike was in quite good shape. Over the years, the key had been misplaced but luckily the steering lock had not been engaged so we were able to manoeuvre and hoist the bike into the back of the van.
Back at the garage, the bike was inspected and although we were unable to run the engine, overall the bike seemed in reasonable condition, although we did find a rodent nest under the seat! Luckily the mice were long gone and hadn’t caused any damage, as they are known to nibble at wiring harnesses causing electrical faults!
Firstly, we needed to replace the ignition barrel, so a complete lock set was sourced as it was more cost effective than just replacing the ignition barrel alone. We replaced the complete lock set and got an additional couple of keys cut as the set only came with one. Using a slave battery (as the original was well past its best) we were able to turn the ignition on and turn the engine over. As expected, the engine didn’t start as the fuel was stagnant. It was reassuring to hear the engine turn freely.
Next, we removed all the upper fairings to gain access to the engine and fuel system. We also noticed that when the ignition was powered up, the fuel system wasn’t priming, indicating a possible fuel pump problem. We removed the tank and then removed the fuel pump, along with the sender unit, and found the pump and internal surface of the fuel tank to be heavily corroded due to the stagnant fuel. The fuel pump was then tested and found to be seized, again due to the fuel. Externally, the tank was in great condition. We internally cleaned and relined the tank to stop rust reoccurring. A new fuel pump was sourced, and the sender unit was cleaned and both were refitted to the tank. The tank was then fitted to the bike and with a splash of fuel, and with the fuel pump now priming, the bike started for the first time in a long time!
Now we had the bike running we could carry out a full inspection. This threw up two additional faults. One – the exhaust system was blowing from around the collector box (catalytic convertor) area. Two – gears could not be selected whilst the engine was running.
We investigated the clutch fault first. The clutch system on this bike is hydraulically operated, and the operation was fine, indicating an issue with the clutch itself. We removed the engine side casing to gain access to the clutch basket and plates. We removed the plates and found the friction material to be heavily deteriorated and, in some places, had come adrift. All the clutch plates, including springs, were replaced and the side casing was refitted. Also, the hydraulic fluid was replaced and bled through. The clutch operation was retested and all gears could be selected with ease. Next we looked into the exhaust fault and found the inlet pipes to the collector box to be badly corroded, and exhaust gases were escaping. The cost to replace the collector box (catalytic convertor) may well have made the entire project financially unviable. The only way to move forward was to repair the system. The system was removed and the affected areas were cut away. We fabricated new intake pipes with stainless steel tubing, and using new gaskets and clamps, the system was refitted, and then tested for leaks. We were very happy with this repair as it was much more cost effective, and due to us using stainless steel, this issue will not reoccur.
Now the bike was running and riding, we could concentrate on the servicing side of things. The bike was given a full service; we replaced the battery, oil and filter, fuel filter, both air filters and all four spark plugs. We also drained, flushed, and refilled the cooling system. We then inspected both front and rear braking systems; front and rear brake pads were replaced as they were worn well beyond their service life. The brake fluid was also replaced in both systems, and bled through.
The last thing to change was the tyres as they were perished due to age. We replaced them with Bridgestone Sports Tourers and balanced both wheels, then refitted them to the bike. Whilst the rear wheel was being fitted, the chain was cleaned, inspected, lubricated and readjusted.
Once finished and all the fairings refitted, the bike was given a MOT, valet and road test. We were happy to report that the bike rode without fault, and looked fantastic. Due to it's rarity the bike had lots of admiring glances and great comments from passing customers.
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