The sons new project 1980 gs850

[Guest]

Gotta love getting those red and white labelled parts Greg, and that paint looks awesome!

If he's got it done by June 1st tell him he's more than welcome to join us too...

 

[ged]

Looking great! I hope its not rude to ask, where did you get the brake pedal from and how much?

Not rude at all, got it from Springwood Suzuki they advertised it on ebay for $39.

Gotta love getting those red and white labelled parts Greg, and that paint looks awesome!

Thanks have been doing a bit of shopping from Mic Hone the shop you spoke about, some of his prices arent to bad, and some cheaper than the states.

If he's got it done by June 1st tell him he's more than welcome to join us too...

Will do Pete................ray:

 

[Guest]

Good stuff!

 

[ged]

Reusing piston and rings. I think the 0.5 means oversize 1/2mm. Started looking for new rings to replace but I dont think they supply them anymore. Looked on all the web sites but no luck. The piston and rings dont look that bad so back in they go.

 

[GSX1000E]

Yes those pistons should measure to fit a 69.5mm bore cylinder. That project is moving right along and going to be sweet.

 

[growler]

great project! i'm along for the ride.

 

[Guest]

Glad to see it coming together Greg! If you're stuck for parts don't forget to try Mick Hone. Although they're best for Kat stuff apparently they have a large amount of Suzuki parts on hand...

Obviously your son's not gonna make it for June 1st

 

[ged]

Yes those pistons should measure to fit a 69.5mm bore cylinder. That project is moving right along and going to be sweet.

Thanks but I just dont think the rings are ever going to be easy to purchase.

great project! i'm along for the ride.

Thanks

Glad to see it coming together Greg! If you're stuck for parts don't forget to try Mick Hone. Although they're best for Kat stuff apparently they have a large amount of Suzuki parts on hand...

Obviously your son's not gonna make it for June 1st

Thanks Pete after you told me about Mick Hone I have being using him heaps for parts.

I have been behind posting the progress of this build because we have had a major engine failure, I will be posting the results shortly. Until then some more pics.





The electrical layout looks different to my bike, must come from another model. The fuse box is not tilted like mine and the ignitor looks different.







New brake lines from Rennsport.

 

[landshark]

we have had a major engine failure,

Thats rarely a good thing

 

[cougar]

looking really good

how much did the New brake lines from Rennsport cost and are the in stock or made to order??

 

[Guest]

Bugger on the engine failure Greg, that's no good!

The rest is looking spot on though...

 

[ged]

looking really good

how much did the New brake lines from Rennsport cost and are the in stock or made to order??

Mate they were about $120 AUS for the four hoses. I think I went for the GS1000s sizes because of the shorter handlebars. I still have the sizes and end attachment directions if you want them.

 

[ged]

Bugger on the engine failure Greg, that's no good!

The rest is looking spot on though...

Thanks Pete I want to jump ahead and get to the engine failure. Will show some more of the rebuild prior to it first.

 

[Guest]

Looks great Greg! Now about the engine failure

 

[ged]

Ok got it finished. Carbs had 117 main jets and the Vance & Hines exhaust instructions said to put 120 in. After I did this bike idled fine but had no mid or top end power. I then changed the mains to 122 and it felt a little bit better but still a delay in the power mid to tops. The spark plugs looked on the lean side. Valves were all checked and adjusted to spec. Carbs were sync. Pics of bike first.













I test rode it first and travelled about 6 klms. Then I told the son to have a ride and see what he thought. Got a phone call from son..........no I thought are you all right did you drop it? Story from son was carbs still playing up, he said he was going about 130klm/hr when bike rear wheel locked up, he then pulled clutch in and came to a stop. Tried to start bike wouldnt turn over. So I hooked the trailer on and collected bike, engine was seized would not turn over, we were both devastated. I didnt take too many photos of pulling it down to find the cause because how upset we were. When we took the valve cover off we found number 3 intake valve shim shattered. All the valve shim gaps were in spec, this shim was an aftermarket shim all the other shims were the old original suzuki looking shims. This one was a brand new aftermarket shim I had purchased off Z1 or a company in Aus that Pete had told me about. Cannot be sure which one. Now I have found another post about a shattered shim on this forum also an aftermarket.

http://www.thegsresources.com/_forum/showthread.php?t=219760




Can we talk about shims here, or do you think I should start up a seperate new topic under another forum section?

 

[GSX1000E]

That 850 is, without a doubt, the best looking 850 that I have ever seen!! :clap::clap::clap:
Now, how did the shim get shattered and what damage did it cause?

 

[Guest]

Wow that's an odd one Greg, bugger! I haven't heard any issues with Precision Shims (the one in Melbourne) and I think most of my shims are from there. I'd be surprised if Z1 used dodgy shims too... maybe just bad luck?

If you read to the end of the other thread, it looks like he thinks the clearance may have opened up too much...

 

[ged]

Yeah I just dont know. Damage caused was a broken cam chain, broken cam chain guides front and rear, damage to cam lobe, looks like all the valves are bent from hitting tops of pistons, lucky no pistons damaged just marks. I am not sure about using these after market shims, the son has told me no shims unless original suzuki. Mechanic mate of his states he has seen it before with shims shattering, original shims have a edge around both sides and the aftermarket ones are straight edge. They just look different, cast maybe not forged?

 

[eil]

Wow, that's some terrible luck after all the work you did. That bike is truly gorgeous!

Shattered shims are not terribly common, even aftermarket ones. That thread you linked to, we already know the root cause there: the guy over-revved the engine which caused the shim to exit the bucket and get mangled up in the valve train. So I'm not sure that one counts as evidence of a bad batch of aftermarket shims or such.

Regardless, hope to see this one back on the road soon.

 

[Guest]

I had a look at Mick Hone's web site Greg, genuine shims are $14.85 each, Precision Shims are $9.95 each... I'm going to be ordering some very soon ready for the next service (pretty sure my exhaust clearances are lower than I like) so I might go genuine this time seeing as there's less than $5 difference!