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Carb Rebuild Gaskets/Supplies

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Rooster

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Hey All,

I'm going through the newbie list of maintenance and am getting ready to do the carb rebuild. I have a few questions and would appreciate some direction.

What gaskets, washers, etc. do I need to make sure I have?

This is what I have figured so far (please let me know what I'm missing):
O-rings + Bowl Drain O-ring - cycleorings.com
Float Bowl Gasket - Boulevard Suzuki? (Any other sources for OEM gaskets?)
Needle Valve Assembly - Boulevard Suzuki
Fuel Mixture Screw (per Boulevard rep's suggestion..?)

Are there any other gaskets, washers, etc. that need to be replaced?

My understanding is that brass parts don't need to be replaced unless they are seriously messed up. Is that right?

Thank you in advance for taking the time to help me out. :)
 
Well, I got a complete rebuild set off Ebay for my 4 carbs for my '80 850L, and it had all the o-rings, gaskets, jets, etc.. Basically, it had everything you needed except for the needle jet.

If you wanna go a step farther, you can go ahead and replace the screws with whatever metric screw set you want(I went stainless hex-head), as well as doing the jets if you want.

My rebuild kit was around $100 shipped, fyi. Here is a good guide to follow for a rebuild:
http://www.thegsresources.com/gs_carbrebuild.htm

Good luck!
 
I suggest getting the O-rings, including the intake boot O-rings, and that's all until you see what's going on inside the carbs. You can cut gaskets from gasket paper easy enough if necessary, and most of the time you don't need anything else.

Good luck

EDIT: woodman posted while I was typing. An updated carb rebuild tutorial is linked in my signature. No need for rebuild kits, just O-rings.
 
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Awesome, thank you! Yea, the carb rebuild tutorial in your sig is the one I found and am using!

I replaced the intake boots, o-rings and airbox boots already. ;) Per the GSR protocol.. So now onto the carbs.

Most everyone on the forum here says to use OEM gaskets, will cutting them from paper be a OEM quality replacement? Can you recommend a good gasket paper?

Also, I want to replace the cover plate philips screws with allen head sockets like I did for the intake boots. Does anyone know what size I need? I'm not an expert so I will measure them and figure it out or whatever but it's always nice to have some confirmation from some gurus!

Cheers.
 
I went to Fastenal and got stainless steel socket head cap screws to replace all the JIP screws. I don't know the size right off but might be able to find out if I didn't throw the invoice away. Cost less than $20 for 64 ss screws. Money well spent in my opinion. You shouldn't need new float needle and seat as the needle is brass, no rubber used here! I made bowl gaskets out of material sourced at NAPA.
 
Do your bowls leak? Are the current gaskets brittle or broken or stuck on the carbs?

If they look alright, just reuse them.

Tank
 
I just did mine and got paper at advanceauto for like $7.00 and a hollow punch set at Harberfreight for like $8.00, used a small plastic cutting board (from our kitchen:D) and a utility knife..took 1-1.5hr. O-ring kit for 20 from Orings.com and a gallon of Berryman carb dip from autozone for $30.00 (which seems wasteful since I'll be lucky if I use it more than once again) but so overall, $60.00 and there done.
 
Walmart has the carb dip for less than $20.
If you get the gasket paper at the auto parts, get the thinner variety (they usually have thin and thick).
Personally, I spent about $15 and got the real thing. A lot less work, less hassle, and they fit perfectly. Look on eBay for an even better price.
 
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If you look at the fiche, the part number has the size of the screw in it. If a part number reads xxxxx-03060 then you are looking at a M3 x 6mm long screw which you can find at places like Ace Hardware, Fastenal, etc.

Alternatively, you can buy the entire kit from Z1 or even Cycleorings.com
 
@brownford - Great thank you. No big deal if you don't have the info on hand. I should be able to figure it out now.

@Tank - No, the current gaskets aren't leaking. I just thought it was bad practice to reuse gaskets once you take things apart. Is that not true?

@slyone - Thanks. Cutting my own is starting to look like the winner. Is the paper from auto supply stores of equal quality to what I would get if I ordered OEM?

@koolaid kid - Great! Thank you, I will go to walmart for the carb dip. Thanks for the tip on ebay too.

@cowboy - Is a fiche the parts list/breakdown? Sorry I'm a newb, I even tried to google what it was, but couldn't find a fitting definiton. From the context I imagine it's the parts list. Also, I bought the o-ring kit from cycleorings but didn't allen head screws that would fit the carbs just the intake boots. Are they the same?

Thanks a ton everyone.
 
Yes it is. Go to Boulevard Suzuki, or any of the dealers, go to their parts area, look at the online parts fiche, select your model/year/bike, and then go into the section you are looking for (carbs, crankshaft, wheel, etc).
 
@cowboy - Great, thanks!

Also I have another question, two actually:

1. The Fiche lists both a Model X and Z for the carbs. How do I determine which I have on my bike?

2. How do I figure out exactly which "G" I have? I noticed there are GL's, X's, Z's and maybe others I'm forgetting.
 
The X and the Z is the year; X being the 81 and the Z being 82.

Past that, post up a picture of the bike and we can help out (stepped seat and almost all chrome will be the L)
 
Here's a pic I took after I put a headlight on it. Unfortunately there's a rag on the seat. Can you still tell which G it is?

photo_zps25d7d0f0.jpg
 
Which "G" do I have?

Which "G" do I have?

Hey all,

I'm trying to figure out which G I have as I'm trying to order parts online and I keep being asked if I have a regular G, a GL, or some others I'm not remembering offhand.

Here's a pic (sorry I took it the other night):
photo6.jpg
 
Just as your signature states... GS650G

The factory service manual has details of each model...

The parts fishe on-line also has details of each model...
 
Rooster said:
I'm trying to figure out which G I have as I'm trying to order parts online and I keep being asked if I have a regular G, a GL, or some others I'm not remembering offhand.

Here's a pic
Click to expand...

Nessism said:
Just as your signature states... GS650G.
Click to expand...
Another part of your question is about the "X" and "Z" that you are seeing in the parts lists. Your signature says you have an '81 (which would be an "X"), but you may have to look at the VIN on the steering step for the ultimate answer.

If the VIN plate is intact and complete, there will be a letter in the lower right corner of the plate that has the letter. If that letter is not visible, look in the upper right corner for the production date. Bikes made after August will likely be for the following model year, so if your bike had a production date of September through December of '81, it is actually an '82 model, which would be a "Z".

One area where it is important to know which one you have is when you order a valve cover gasket. The '81 650s have a 16-bolt cover, the '82 and '83s have a 17-bolt cover. Obviously, the gaskets are different.

.
 
Thank you for the answers!

Yea Nessism, that's what I thought but I developed a doubt when I started looking for parts. Thought it'd be less newb to double check than to have to return ordered parts!

Thanks again.
 
Here's you a service manual for the '81 650GX model, for the '82GZ model , it's listed as supplementary manual towards the back, identifies stuff that different from the '82 model. You can download it and save it to your computer.
http://www.mtsac.edu/~cliff/storage/gs/GS650GManual.pdf

Here's a parts fische for the carbs for the '81 model. Item 33 for float bowl gaskets.
http://www.boulevardsuzuki.com/fich...y=Motorcycles&make=SUZUKI&year=1981&fveh=2127

And for the '82 model. Carb bowl gaskets are the same. Item 34 for float bowl gaskets.
http://www.boulevardsuzuki.com/fich...y=Motorcycles&make=SUZUKI&year=1981&fveh=2127

Those OEM gaskets at Boulevard Suzuki are expensive, $6.98 each. But at Z1 you can get a set of 4 for $14.80! :idea:
http://www.z1enterprises.com/ItemDe...Bowl+Gaskets+Mikuni+BS32+4-Pk+&item=KL18-2612

If you do use the manufacture date to determine the model, you may have to go back to August, my '79 GS1000EN has a manufacture date of August '78, stamped as 8/78. And I have found at least one issue where it didn't have an engine manufacturing update the newer '79's had.
 
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