Some assembly required

[7981GS]

Made a little progress today after getting Jenny situated.
Initial peek into the float bowls:

Hard to tell but this enricher circuit was plugged solid.
A piece of fishing line and some brake cleaner opened it up:

All four carbs are supposed to have a cap on this port in this application (Another vacuum leak):

Under those caps, without the diaphragm/slide installed, you see where O-rings are supposed to be.

One was missing and the remaining three looked like this:

Harbor freight generic $3.00 O-ring set to the rescue! The smallest one, RO-1 was a perfect fit!

The 30 pilot jets that came out, hard, are way too small for this engine.
As I am going to remove some of the smog crap, and didn't have the 37.5's that I thought I had,
I chose to install 40's. The 120 mains are being replaced with 122.5's.
I put anti-sieze on the threads of both the pilots and mains.
This is what they look like with the new jetting:

I was tossing around the idea of changing the needles with some Dyno jet ones that I have on hand and decided to
up the needles .49mm with 3mm flat washers instead. (Mic them! I had from .46-.54mm thickness washers.)
The stock plastic spacer Mic'd out to 2.52mm so now the needles will be 3.01mm up.

Going for some rides with Tom MLC tomorrow so I may not get back to them.

 

[Etcheberri]

i like how you detail the process for your carbs.
man those small o-rings were shot! how come they get ripped appart like that?

 

[7981GS]

All of the carb parts have been gathered up so it was time to put them back together.
I opted for the 32.5 pilot jets with the bleed holes, one shim under the jet needle and 122.5 main jets.
(Basically, 1+ on each of the pilot, needle and mains)

With the help of some O-rings from Cycleorings.com that I keep in stock for the CV carbs,
I found that the "D" O-rings fit the enricher tube seal on these carbs and
that the fuel inlet O-rings worked on the needle/seat seal:

Installed:

Now is a perfect time to saturate the vacuum bellows with rubber protectant inside and out to keep them supple:

Installed with new slide springs and O-ring:

When I took this beast apart, I could have sworn that there was more room than this:

Have I mentioned how much I HATE stock air-boxes and LOVE pods?
What a complete PITA!!!

Anyway, she fired right up!

More later...

Daniel

 

[7981GS]

After installing the new Iridium plugs and fixing the plug wires/boots,
she wants to jump off of the center-stand!
Camera is not cooperating or I would post pic's of the old screwed up plug wires/boots.

Daniel

 

[7981GS]

The 32.5 pilot jets were too fat for the stock bike.
I traded them out for the 30's today and with the raised needle and 1 size larger main jets...
it rips!!!!!

Daniel

 

[Smokinapankake]

You suck. You suck. You suck. I totally dig these GSX-G's and would love to get my hands on one, but after watching all the work you have to do to clean carbs I have to rethink my position.....

Nah. You suck! Well done!

 

[7981GS]

I ordered pods for it today.
It will be back to the drawing board again after I get them.

I had the carbs out and in, in under 3 hours this last time.
I HAD to take all of the other stuff off to get some swinging room to get the manifolds out the first time.

Daniel

 

[Guest]

Won't run with pods Daniel?

 

[7981GS]

Won't run with pods?

LOL!

You know. Just like your 1230 doesn't run with them either. :-\\\

Daniel

 

[Guest]

LOL!

You know. Just like your 1230 doesn't run with them either. :-\\\

Daniel

Runs like poo poo
Going on a ride with Jim today!

 

[7981GS]

Baby gets some new shoes!

Removed the old tires (10 years OLD! )

Looking MUCH happier with new shoes!

These Michelin Pilot Road 3's are even sipe'd for the coming winter riding! :teeth:

Tomorrow, she gets the new handle bar. :dancing:

Daniel

 

[HammerHead]

Baby gets some new shoes!

Removed the old tires (10 years OLD! )

Looking MUCH happier with new shoes!

These Michelin Pilot Road 3's are even sipe'd for the coming winter riding! :teeth:

Tomorrow, she gets the new handle bar. :dancing:

Daniel

Nice, very nice.................

 

[hampshirehog]

Ha ha. I didn't see the strap on the handlebars at first and thought your bike was perfectly balanced on the centre stand, sitting there with both wheels off.

 

[7981GS]

I have been finding all kinds of uses for that engine lift working on scooters.

Daniel

 

[Nuitdevotremort]

I can recognize those HF digi calipers from a mile away. lol

 

[7981GS]

As this model uses 1" handle bars, I had to be creative as all that I had were 7/8".
I found a set from a Victory motorcycle and cut 1" off of each end to make a bar that is much more to my liking.
Instead of 28" across, it is now 31.25" and about 2" higher.
I was in too much of a hurry to go for a test ride to take a pic of the stock versus the new bar.
Perhaps these pic's can give a clue...

With the Victory bar, does that now make it a "Cruiser?" LOL!

Chilly video (mid 40's out.) of the road that I was going down were the secondary drive seized on the 850.
The camera was NOT supposed to show the speedo and tach as it was mounted high on the new bar.

http://www.youtube.com/watch?v=g4Puq_VFgtw

Good thing that the speedo reads in kilometers.
I still have to find out what is wrong with the forks...


Daniel

 

[7981GS]

Stock bar versus the Victory bar.
Even using a Victory throttle as the original one was cracked and glued together by one of the PO's.:

This is where the camera was mounted.
I will have to find a better location or raise it and move it forward so as to not show the gauges.

Changed the fork oil and added 1/2" of pre-load to the stock springs today...

The PO had several different kinds of fasteners holding the fender/fork brace on!
I HAD to fix that!

Took the Wife out for a ride now that it is safe with new tires and suspension.
I was worried about the seating position for her with the higher rear pegs and seat.
She said that it will be quite comfortable for much longer rides.

Daniel

 

[NeyborDayfid]

I don't mind seeing the gauges. I started watching that video and then turned the light off, enlarged the screen and just sat in front of my computer and took the ride with you. I even paid attention to the gears! Thanks for that. I love that part of the country.

 

[7981GS]

ND, then you noticed the habitual letting off of the throttle when any vehicle is spotted. That road is posted 40 mph. Whoops!

Around here, they come in all sizes and colors! Marked and unmarked!
Makes it difficult to have a safe/fun ride.

Take these rides, in HD, if you liked that one:

http://www.youtube.com/watch?v=CywPRMQ0l48 (Had to mount the camera on the tank)

http://www.youtube.com/watch?v=Udmnz58_yHs (Wife on back. 16 miles.)



Daniel

 

[NeyborDayfid]

Geez, you've got some real jerks commenting on your vids. I enjoyed both of those. I don't care where you keep the rpm's.
I did notice you laying off the throttle with MOST the cars but there were a couple you seemed to identify as non-law-enforcement and accelerated right past. Beautiful weather for those rides. Here in Portland the weather is now turning to liquid-sunshine and will most likely remain that way for the next 6 months. The track opens in April. That's my main area of concern. :dancing:
Keep warm out there in the desert and thanks for the vids.