1980 GS850G Restoration

[glstine]

Cam chain tunnel o-ring. Been there.

That's it. Saw it sitting on the bench after I got all of the nuts torqued down. Worked out for the best though, otherwise I would have tried drilling out the broken bolt with the head on and I don't think that would have been very easy.

 

[etpetnel]

I paid $150. I figured that was a good price since there was a title (we will see in the end I suppose). It is really not as bad as it looks in the pics, most of the major parts are there. The gas tank is also very clean which surprised me, I expected it to be full of rust.

Great price, I just bought a GS850G here in SA, and paid equivalent to about $1000 for it. The condition is similar to yours, I would say, and already have the carb in for repairs, after trying to sort it myself didn't solve the problem. And right now I'm busy removing the rust from the tank.

Etienne Nel
SA.
Gs850G

 

[Guest]

Looking very nice. What paint did you use on the crankcase?

 

[glstine]

I used Dupli-Color Engine Paint. I used it on my 550 for the cylinders and head and it seems to hold up very well.

 

[rustybronco]

Got some more done. Got the cylinders and head painted, new valve seals, valves lapped and installed.

Ready to put the cylinder block in.

Cylinder block on and ready to put the head on (can anyone see something wrong with this picture?)

Sorry that I'm a little late to the party, but that green gasket sure has me worried.
http://thegsresources.com/_forum/showpost.php?p=1260687&postcount=33

 

[glstine]

I just read that thread today. I am planning to get some OEM gaskets to keep on hand.

 

[rustybronco]

If the hasn't been started, I would replace the base gasket and both o-rings "now" rather than later.

 

[glstine]

Boy this thing is dragging out even though it seems I spend a couple of hours a day (at least) working on it. I went ahead and took the top end off to replace the base gasket with an OEM.

This is what the Athena gasket looked like without the bike even being started (I can't say I know for sure what it should look like, but this looks bad).

Got the carbs dipped. Went ahead and painted the bodies and polished the caps and bowls. I put an engine clear coat on the caps and bowls so hopefully they will stay shiny for a while.

Got the stator in and completed the engine portion.

Rebuilt the starter and have been spending a lot of time painting things. Seems like every time I look into the bags and boxes I have parts in I keep finding things that I need to paint that I didn't think about. I am just about done painting now, just a few items left. Now it is just a matter of getting everything bolted back together.ray:

 

[Tim Tom]

Its looking great! Way better than my 850 looks (even without any bodywork or wheels ) I keep telling myself that one day I'll get around to making it look as nice as it rides... But then I'd have to stop riding it. :-k

Back to your build though, looking sweet! If you put the same amount of attention to detail into it as the engine and chassis your gonna have one heck of a nice looking machine.

 

[JEEPRUSTY]

I haven't updated this thread in quite a while but I have been working on it. Seems like delays everywhere from kids activities to humidity to high to paint anything (I actually considered painting some stuff in the utility room one day but I figured the wife would kill me).

Got everything off of the frame and started getting it cleaned up

Stripped the old paint off using wire wheels on the angle grinder. I will never ever ever do that again. For the cost of all of the wire wheels I went through I probably could have paid to have it sandblasted. Not the mention the mess it made.

Nice new paint job. I used the VHT epoxy paint I saw recommended on a thread here. Turned out nice. We will see how it holds up.

Swing arm and shocks back on. I just painted the old shocks, I will eventually get some progressives.

The case covers were pretty rough.

But they shined up pretty nicely.

Got all of the gunk of the engine. I gave the cylinders and head to a friend to bead blast for me.

I see an unrusted jeep how is that possib;le?

The 850 engine would be a nice winch motor for it.

 

[glstine]

I see an unrusted jeep how is that possib;le?

The 850 engine would be a nice winch motor for it.

My poor jeep doesn't see much action these days. It doesn't help that they shut down the only off road park that I know of that is nearby. Not many places to off road in the city. I've considered selling it since I don't drive it much anymore, but I just can't bring myself to do it.

 

[JEEPRUSTY]

My poor jeep doesn't see much action these days. It doesn't help that they shut down the only off road park that I know of that is nearby. Not many places to off road in the city. I've considered selling it since I don't drive it much anymore, but I just can't bring myself to do it.

god i live in the woods and am scared to drive cos moose laugh at my decaying bodywork

that and the new JKs have taken over

cant ever inmagine selling a rig that can be turned around on a skidder trail
hummer indeed!

 

[Nessism]

Bikes looking great! Smart man ditching that Athena base gasket!

Got a chuckle over your comments about the frame stripping. Been there, done that. No fun.

Keep going and please continue to share.

 

[BassCliff]

Hi Mr. glstine,

Wow! Great work! Keep it up! Thanks for sharing.


Thank you for your indulgence,

BassCliff

 

[glstine]

Thanks for the comments. I should be updating more frequently now. Last night put the starter in, bench synced the carbs and put them on, put new boots in the airbox and put that on and started tightening the clamps on the boots. Then noticed, I didn't put on the fuel and vent lines or cables. At least the carbs are a whole lot easier to get on and off than the 550 carbs are.

 

[glstine]

Work continues. I got the wiring harness all cleaned up and installed (cleaned every connector with sandpaper and contact cleaner)

I had to replace the two handlebar switch plugs, one was smashed, the other was melted. I also added wires to do the coil relay mod.

Put in the R/R, wired it as recommended in the R/R replacement guide. Also got the fuse box, solenoid and ignitor in.

And here is a sneak peak of the finished product

Just imagine it with all black wheels and yellow calipers and black lettering on the emblems. I am going to try and start it up this weekend and pending success I am going to take the wheels back off and get them painted and order tires and brake lines, I should then be finished (I think).

 

[Flaming Chainsaws]

Great job! Now get them wheels painted

 

[paul1875]

bike is looking great mate

 

[Guest]

I like the yellow. It is different and will make your bike stand out. Looking foward to finished bike.

 

[glstine]

Thanks for the comments. Had a bit of a buzzkill today, not getting any spark. Oh well, I'll start troubleshooting tomorrow. I do have a question for the experts on here though. I bought what I thought was a stock L model exhaust.

(Looks like a stock L exhaust)

When I was tightening up the bolt at the back on the right side I noticed this:

Can anybody tell me what is up with that?