1983 gs 850 GL

[Crazy Carlos]

Update on my progress!

Update on my progress!

So, things got very busy for me as I've been working 60 hours a week for the last 6 or 7 weeks. Anyway, I got lucky enough to have 2 days off this weekend and so Zach and I got back to the bike yesterday and today. We've completely stripped and painted the frame, Disassembled the front and rear end. I'm currently dealing with some issues with the hub so I'm looking for some advice:

When stripped the frame we took the rear end completely off by just taking the swing arm off. So I had a rear tire with the rotor, caliper, swing arm, hub, and drive shaft still attatched. It sat in my car port for a couple weeks and then all of a sudden one day I moved it from one side to the other and the gear oil started leaking from the outside rim of the hub. I quickly drained the oil. Today I was looking for the leak. I had the cover off and propped the hub up as if it was sitting on the bike and filled it back up. All I could find was a slight seep of oil but not even enough to drip past the edge. Has anyone had these same problems before? Also if I need to take this thing apart does anyone know where to get the special tools?

Aside from the hub issue things are looking up and I'll have pictures up here in a few hours. Hope all is well and everyone is riding safe!

Carl

 

[Crazy Carlos]

pictures

pictures

 

[Dogma]

I know these will leak out the vent if you over-fill them. Since there is a vent, they will also leak if you turn them upside down. I wish I could tell you where that vent is so you could see for yourself, but I've never tried to find it. My guess is one of those two holes near the top of your last pic. I guess you could fill it with oil, then turn it over and find out for yourself.

Of all the petrochemicals associated with bikes, gear oil is the only one I don't like the smell of.

 

[Crazy Carlos]

I'm pretty sure that is the case! the two holes that lineup across from each other are threaded and the one off to the left is not. I did notice a real slow leak when I did flip it over. I'm just surprised that just by chance, if that is the only reason it leaked, that I didn't store it upside down until the last time I moved it. I guess where I'm at now is wondering if I should disassemble the whole thing and clean it up since I've got it apart or just slap it back on after I clean what I can see.

 

[Dogma]

I'd just clean it up and make sure it was properly filled when it's time to ride. Very few people have had mechanical issues with a final drive.

 

[Crazy Carlos]

so could I ask you if your starter cover from the left side of that parts bike is still available?

 

[Dogma]

Steve just took the rest of the engine a few weeks ago. Thanks for asking. I need to round up the rest of it and have a sale thread. I don't know what Steve's plans are for it, or whether he is willing to part with the starter cover (stator cover?).

 

[Crazy Carlos]

I guess they're both right there. I've been wondering which is which and it appears that both the starter motor and generator stator are right there... either way it's on the left side... sorry.

 

[Dogma]

In general, GS terminology has the aluminum cover on the left end of the engine as the stator cover, with the starter cover being the stamped steel cover on the back of the engine, just behind the cylinders.

 

[Crazy Carlos]

oh! okay. ha ha. I'm still learning... alot. Definitely a fun project though. The weather's getting nice and I'm really looking forward to putting this beast back together!

 

[Crazy Carlos]

Help!

Help!

I'm trying to decide what gasket set to buy. I've found a "Top End Gasket Set" for 62 bucks on ebay and then there's the "Athena Gasket Set" on oldbikebarn.com for 92 or so. I'm a firm believer in the belief that you get what you pay for; I just don't know my stuff when it comes to this kind of thing. Anyone wanna steer me in the right direction here? I'd appreciate any help!

Thanks

Carl

PS re-assembling the front and rear end tomorrow and possibly throwing them back onto the frame! Pictures to come...

 

[cowboyup3371]

You might want to steer away from OldBikeBarn as it's been pretty rough dealing with them for some of our folks. Read the reviews and deadbeat sections on the forum here about them.

Why not call up Z1 or even Boulevard Suzuki and see what they have to say about a good OEM kit?

 

[Crazy Carlos]

reassembling

reassembling

just a bit for now. Gotta get some new swing arm bearings which is gonna be a few days out for those to come in. Here's where we're at:

 

[DannyMotor]

Looking good! Liking the all-black rims.

 

[Crazy Carlos]

Chugging along

Chugging along

Slow and steady right? I've been out of work for a mandatory training course so it's been slow. I just got the oem gasket kit from Z1 and will be getting that started next week I think. Here's some photos of the latest. I've been told that I need to sand blast the tank in order for the paint to look even. I'm planning on just painting the tank the same as the frame. Any advice on a different method?

 

[Crazy Carlos]

September 2012 update

September 2012 update

So my dad came up and we tore the engine down. Found a couple of cracked valves but to the best of our knowledge that's really all that needs some real attention. (aside from piston rings and gaskets) Everything else looks salvageable. Z1 can get me the valves for a hefty price 34 and 47 a piece. Anyone know any better places or options to find some valves? here are some pictures!

 

[Good Times]

Glad you're back at CC!

 

[7981GS]

So my dad came up and we tore the engine down. Found a couple of cracked valves but to the best of our knowledge that's really all that needs some real attention. (aside from piston rings and gaskets)
Everything else looks salvageable. Z1 can get me the valves for a hefty price 34 and 47 a piece. Anyone know any better places or options to find some valves?

Have you tried APE or have Manley or Ferrea make some custom valves?
(Larger intakes and stock exhaust.)
Or http://www.boulevardsuzuki.com/fich...y=Motorcycles&make=SUZUKI&year=1982&fveh=2144
Or a used head.

The custom-made valves will actually cost less than stock parts.
The used head will save even more.

Eric

 

[Crazy Carlos]

I have another question... Looking at this photo, which is a glimpse at what's underneath my starter, I see this hole (currently plugged with an ear plug) There was all kinds of pine needles and dirt under there and now I'm worried that it got into the crank case through that breather hole. My plan wasn't to take apart the crank case. Any pointers or words of encouragement? thanks!

 

[Good Times]

If you're worried about it then take the oil pan off. Easiest thing to remove and get a good look in the crankcase. Wouldn't hurt to replace the gasket anyway.