• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Spent some time in the "man-cave" - From Wreck to Restoration

  • Thread starter Thread starter BassCliff
  • Start date Start date
How about xray pics prior to surgery of your knee :D.

I just came back from a crash on the interstate. (yes i'm working today)
Lady in van, on the side and slid approx. 200' might lose her arm. I still say BassCliff is very lucky. Send pics to the company that made your gear. Who knows they might send you new????
 
New intake boots and O-rings

New intake boots and O-rings

Hello friends,

Well, while waiting for new brake pistons I decided to go ahead and repair the air intake system on Jessie. I took lots of pictures and will be writing up a pictorial guide. I was surprised that this procedure is not difficult at all and anyone who has not replaced their carb boots in the last 25 years or so should not hesitate. Let me hit the highlights of my time in the "man cave" this evening...

We start by removing the airbox. Take breather hose off. Loosen up the clamps on the airbox boots and the two bolts that hold the top of the airbox.

intake_repair05-1.jpg


After everything is loose it practically falls out. Take it out from the right side of the bike being careful not to jerk any wires or break the snorkel on the back.

intake_repair14.jpg


I'm glad I got new "airbox to carb" boots...

intake_repair16.jpg


Then you loosen up the clamp on the intake boots...

intake_repair18.jpg


And the carbs separate very nicely...

intake_repair25.jpg


Then you fiddle with the throttle cable and choke cable to take them off. Don't forget to reconnect them before you put the carbs back in the new boots.

intake_repair26.jpg


Then you get out your trusty impact driver and wail away at the lousy phillips head bolts...

intake_repair43.jpg


I thought the lower bolts on #2 and #3 were going to be really tough because there's not much room to work in there. But if you just tap the boots around "lefty-loosey" then the bolt will loosen up enough for you to get it out. Whew!

intake_repair49.jpg


This was the bad boot. Some hack stuck an odd screw in there and stripped the threads enough that I wasn't ever able to sync the #4 cylinder.

intake_repair45.jpg


And here's the fresh batch of parts, all the boots, new clamps, fasteners and O-rings from Robert Barr, etc.

intake_repair50.jpg



Thanks for the note Mr. Barr. That's 10 pictures. I'll put up a few more in the next post to show you how it all turned out.


Thank you for your indulgence,

BassCliff
 
Last edited:
Hi,

Here's the airbox with new boots...

intake_repair66.jpg


Here I'm putting on the new intake boots with Robert Barr's new fasteners. Very nice fasteners...

intake_repair54.jpg


Don't forget to reattach the throttle and choke cables before you fit the carbs. The carbs practically jump into those nice, fresh boots...

intake_repair59.jpg


And here they are with the cables attached, clamps tightened, all the hoses and wires tucked out of the way, ready to accept the airbox.

intake_repair60.jpg


Here's the airbox going in...

intake_repair68.jpg


Fitting the airbox took some wiggling and giggling, and a little help from my friend...

intake_repair69.jpg


And now all the clamps are tight, airbox sealed, hoses in place, etc...

intake_repair74.jpg


Now I've got to move the petcock and fuel gauge send unit over to the new tank. Then I can try out my Morgan Carb Tune. By then the brake pistons should be here.

Since I've got space left in this post, here's a couple of gratuitous shots of the new tail section with my old, freshly straightened, luggage rack...

intake_repair01.jpg


And the freshly painted fender...

intake_repair77.jpg


It was a manly time in the garage I had, yes sir. Thanks for looking. I'll keep you informed of further progress. My brake pistons are due here on March 11th according to the UPS tracking data. Then it's brake bleeding time!


Thank you for your indulgence,

BassCliff
 
Last edited:
Hi,

I forgot to mention, as long as I had the carbs off I checked the float height too....


intake_repair39.jpg


I set them just as close to 22.4mm as I could get. A couple were a little low.


Thank you for your indulgence,

BassCliff
 
Nice.

Nice.

You always take such great pics and they speak a thousand words so that was just about a magazine right there.:D

Glad to see all the progress. Have a great day.
 
I see what you mean about Jessie having a "small" leak from the cam chain adjuster. I'm going to replace the o-ring for the oil pressure switch while i'm at it. Thanks for the link.
 
WOW very nice work there BassCliff!!:clap:

I hope you are adding these to your website as well. :D

Time comes for me to do those things I know where to look for help.:)
 
Cliff,
Excellent guide! I am sure its going to be referred to by many.
Glad to see Jessie is nearly back on the road!
 
Cliff,

I just noticed that your "L" exhaust does not have the center opened up like my 1100 has. I wonder if anyone has a stock 850L or 650L to compare the megaphone differences.

reassembly0217-1810_19.jpg
 
82Shafty said:
Cliff,

I just noticed that your "L" exhaust does not have the center opened up like my 1100 has. I wonder if anyone has a stock 850L or 650L to compare the megaphone differences.
Click to expand...

Hmmm, I hadn't noticed. Should I drill it out? Is this necessary? Is this a popular mod? :confused:


Thank you for your indulgence,

BassCliff
 
Last edited:
I hope these are the last parts I need!

I hope these are the last parts I need!

Hi,

I got home from work and found these. Yay!
thumbsup.gif
woohoo.gif
hat1.gif


Two new piston sets and assorted exhaust gaskets...

new_partsr02.jpg


And a tinted Slipstreamer Spitfire S-06 deflector sized windshield...

new_partsr01.jpg


Unfortunately, I've two computers in my home office to fix before I can play in the man cave. :(

One computer gets a BSOD and the other won't boot at all. I'd better get crackin'. :)


Thank you for your indulgence,

BassCliff
 
BassCliff said:
Unfortunately, I've two computers in my home office to fix before I can play in the man cave. :(

One computer gets a BSOD and the other won't boot at all. I'd better get crackin'. :)

BassCliff
Click to expand...

Have you tried yelling or hitting them. That usually seems to do the trick :D :-\\\

There's nothing like coming home to a brown box full of motorcycle parts.
 
Theo said:
Have you tried yelling or hitting them. That usually seems to do the trick :D :-\\\
Click to expand...

One of my favorite techniques is called "impact maintenance".
Hammer3.gif



There's nothing like coming home to a brown box full of motorcycle parts.
Click to expand...
clap1.gif
clap2.gif
nod.gif
Yes04.gif



Thank you for your indulgence,

BassCliff
 
BassCliff said:
Hmmm, I hadn't noticed. Should I drill it out? Is this necessary? Is this a popular mod? :confused:


Thank you for your indulgence,

BassCliff
Click to expand...

I'm going to be out of town tonight, but tomorrow I will get a picture of up my factory setup with the open center... I know Roadrash's is the same and his for sure hasn't been touched.

I'm wondering if your pipes are from a 650???
 
82Shafty said:
I'm going to be out of town tonight, but tomorrow I will get a picture of up my factory setup with the open center... I know Roadrash's is the same and his for sure hasn't been touched.

I'm wondering if your pipes are from a 650???
Click to expand...

Hi,

I asked over in the Tech Section and got a few pictures. All the others have the open center. I was told these pipes were from a 1980 850GL. They fit perfectly. Maybe I'll get out to the garage tonight and read the info stamped on them. I forgot to do that last night. :o


Thank you for your indulgence,

BassCliff
 
Brake update

Brake update

Hello friends,

I was able to put my front brake system back together this weekend. Rebuilt calipers, new pistons, new banjo bolts, new crush washers, and new Goodridge braided steel lines. I got them bled pretty well and the lever feels pretty good.

DSCN1016.jpg


I'm going to see if I can get the brakes a little tighter. Then I'll install the petcock and fuel gauge on the new tank, sync the carbs, finish up any last minute details, and I should be riding to work on Monday morning. :dancing:

It was really fiddly trying to get the pistons back inside the calipers with the new rubber. I ended up using a couple of plastic-coated paper clips. One to hold up the inside edge of the dust cover, bent over the top of the caliper, and the other I used to lift the cover up around the piston. The first one took almost an hour. The next one took 5 minutes. :)


Thank you for your indulgence,

BassCliff
 
You must log in or register to reply here.

Similar threads

Kiwi Canuck
Kiwi Canuck's 1981 Honda CT 110 Restore
2 3 4
Replies
69
Views
6K
Kiwi Canuck
Kiwi Canuck
D
85 GS550 light rehab over the winter.
Replies
12
Views
1K
JEEPRUSTY
J
A
Got in a terrible bike accident yesterday
2
Replies
21
Views
2K
syafi
S
Back
Top