1980 gs850glt

[ZenShenron]

Earlier this month I purchased my first bike in not running condition, hope I didn't get to over my head with this one.

The PO told me it was not getting any spark in cylinder number 1 and thought it might be a coil.
After much (and still more to do) reading on these forums and a few other places I have started to try and bring it back to life.
Being the kind of guy who loves encouragement and advice from others I will attempt to document the process here.

Bike sat for 2 or three years and the tank still had fuel when put away, so first order of buisness was tank and carbs.
Noticed right away the petcock was leaking and got a replacement from Z1 Enterprises knowing that the fuel had at this point probably make its way to the crank case.
Took the carbs off and started the cleaning process dipping and cleaning untill I got to carb #3 when I noticed this.

Not sure if it is repairable but a big thanks to terrylee for having a full set in very nice condition he was selling at just the rite time, so now I will keep the originals as spares.
I purchased a new battery, plugs and boots and noticed an immediate improvement in the reading I was getting from my coil secondaries so hopefully that will have solved the no spark issue.
While I wait for funds to get more of the parts I need I decided I would polish the already nice looking bit on the carbs, here are a couple of before shots.


Here are a couple of the cam covers before.


And in progress.

 

[Gold01ca]

Keep it up, you're doing good work there!

 

[Vmass]

Welcome and good luck with your project.

 

[terrylee]

Glad to help with carbs., worked out well for both of us I hope. Looks like you're headed in right direction. terrylee

 

[ZenShenron]

Another fine day to be out wrenching on the bike, got a few things done this weekend.
Did a bunch of swapping of valve shims and know exactly which sizes I need to get to bring them back into spec.


Was expecting to inspect the condition of the points while I had the cover off, and this is what I found.


Since I have it off the bike, now would be a good time to clean up my airbox, so a good cleaning strip down to bare metal and a few coats of VHT Satin Black.


Filter element seems to be in good shape.

 

[Steve]

You are missing the snorkel that goes up the back of the airbox.

Yes, you do need it.

.

 

[GSX1000E]

Change out your stock 115 main jets for 120's and it will run just great. Z1 Enterprises sells all four for less than ten bucks.
(Up one size because you are in Rhode Island and ride at Sea level and one size for the missing snorkel)

 

[ZenShenron]

Doh!
I spent all that time making it pretty, and now it looks like I am going to have to get another airbox.
It does not look like something that was ever sold seperatly and might be a pain to a replacement, never mind getting a new one on there.

You are missing the snorkel that goes up the back of the airbox.

Yes, you do need it.

.

 

[jsandidge]

Change out your stock 115 main jets for 120's and it will run just great. Z1 Enterprises sells all four for less than ten bucks.
(Up one size because you are in Rhode Island and ride at Sea level and one size for the missing snorkel)

Sorry to hijack your thread, but I have a question for GSX1000E. I ride at sea level too, and my bike seems to run lean. I do have a snorkel though. I'm running stock 115 main jets. Should I try 1 size larger? What about the pilot jets?

 

[bbjumper]

You are missing the snorkel that goes up the back of the airbox.

Yes, you do need it.

.

What for, Air can get in through vents on the bottom.

 

[JTGS850GL]

Just what does missing the snorkel cause? The reason I'm asking is because I have one with a missing snorkel as well.

 

[ZenShenron]

It acts as a meter of sorts restricting the air flow, also it smooths out the flow and sucks it in from a less turbulent location(under the seat).

 

[GSX1000E]

Sorry to hijack your thread, but I have a question for GSX1000E. I ride at sea level too, and my bike seems to run lean. I do have a snorkel though. I'm running stock 115 main jets. Should I try 1 size larger? What about the pilot jets?

PM sent. And do not go up on the pilot jets.

 

[ZenShenron]

Sorry I missed this one.
I think for now I would like to stay as close as possible to stock, as I am a new rider and not looking to start modding the bike yet.
The suggestion for riding at sea level while might be a valid point, but I do plan to ride some longer trips eventually and do not want to shoot myself in the foot if I were to take it into some higher elevations.
I have been doing a lot of reading and have come across a few posts about some loss of power in strong cross wind or buffeting conditions like when a big truck goes by, and I think this might be helped by the snorkel drawing air from a more sheltered location.
Also it may help keep some dirt and road debris out of the box.

Change out your stock 115 main jets for 120's and it will run just great. Z1 Enterprises sells all four for less than ten bucks.
(Up one size because you are in Rhode Island and ride at Sea level and one size for the missing snorkel)

 

[Steve]

The suggestion for riding at sea level while might be a valid point, but I do plan to ride some longer trips eventually and do not want to shoot myself in the foot if I were to take it into some higher elevations.

There will be no problem climbing to elevation with jetting set for sea level. With the less-dense air at elevation, the slides don't get lifted quite as much, meaning that the carbs do a reasonable job of compensating.

However, for those who live at higher elevations and re-jet accordingly, if they come down for a visit, they might be running a bit lean.

I have been doing a lot of reading and have come across a few posts about some loss of power in strong cross wind or buffeting conditions like when a big truck goes by, and I think this might be helped by the snorkel drawing air from a more sheltered location.

You would be much more troubled by turbulence if you had pods, instead of the stock airbox. It is more a matter of where your VENT tubes end up, rather than the airbox source. Keep your vent tubes routed into relatively calm air and you will be fine. In case you hadn't noticed it yet, there is a rectangular loop on the back, right side of the airbox that is meant to hold the vent tubes.

.

 

[ZenShenron]

Well I must say that old gasket was a PITA to get off.
Need to get some new half moons but got it all back together this weekend and fired her up for the first time WOO HOO!!
Still some issues to sort thru but just hearing it run is a milestone for me.
Still on the to do list are:
Get the electrics sorted, PO kinda hacked it up and turn signals were not working. Clean contacts and grounds.
Check brakes and master cylinders, lines look new and seem to be in good shape and brake pads are new front and back supposedly but need to check for myself.
Tires, front appears to be new but need to check the date codes. Will most likely replace with new.
Go thru the stator tests, getting approx 12.8 volts at the battery at about 3-4k rpm but need to clean all contacts and go thru the tests.

 

[ZenShenron]

Well past time for an update.
I have mostly sorted the turn signal issues and have them all working.
There must be something shorting in the rats nest that is the headlight bucket because the fuse keeps popping on me.


The front tire is new and the date code is only a few years old but the rear needs replacing.
Had some oil seepage from the front fork seals so decided to get that done.
After taking the front end apart, I am glad my decision to ride it for the last bit of the riding season did not end badly.
This is all the oil that was left in the forks, almost none.

Those seals were a bitch to get out.
Of course since I had them all apart I decided now was the time to make them shiny, so have been working them for a few weeks now in my spare time.
Lots of work into them here are some pics of my work in progress.












I have everything I need to put it all back together, just need to get them looking nice, tho to be honest the pictures really do not do justice to the way they are sitting now.
I have hand sanded and filed all of the rough casting marks and smoothed them in preparation for the buffing wheel.

 

[Guest]

I might have an airbox and possibly a snorkel for an 81/82 850. When I was re building my 81 850L I bought several boxes of parts from someone that had dismantled a bike. They came in real handy at the time. You can PM me and you can have them for the cost of shipping. Other than that, if there is a MC scrapyard near you, it might be worth checking out.

 

[wymple]

That snorkel seemed to have made a considerable difference on my 850 in crosswind situations. Try to find one.

 

[mikerophone]

I might have an airbox and possibly a snorkel for an 81/82 850....You can PM me and you can have them for the cost of shipping.

Phred, if ZenShenron doesn't need the airbox, I might. Obviously he has dibs, but I may need it if not. When tearing down my 81 850 last night I noticed the airbox side boots are in pretty bad shape and will need replacing. The filter was also completely disintegrated.

I'll PM you as well.