Help me get this thing on the road finally! (Diagnostic videos inside)

[Guest]

I'm starting to get frustrated but I know you all will be able to help me out, I've learned so much already.

It's an 81650G with 14k on the clock just picked her up. Things I've noticed:

White smoke out of the left pipe only
all plugs were fouled and smelled oily
at one point I think there was gas in the oil from petcock but only idled shortly like that
a lot of grime on upper breather house area (don't know if its just cause it's 30 years old)
choke is frozen
starts up fine.

Here are some videos:
http://s1072.photobucket.com/albums/w364/beardswithfriends/?action=view¤t=IMG_0732.mp4

http://s1072.photobucket.com/albums/w364/beardswithfriends/?action=view¤t=IMG_0733.mp4
second start up and rev:
http://s1072.photobucket.com/albums/w364/beardswithfriends/?action=view¤t=IMG_0734.mp4

So far I've cleaned and oiled the filter which looked dirty
replaced the plugs with new ones (these videos are the first run with new plugs)
pulled the carbs and checked the floats and they weren't stuck. overall looked pretty clean.

Where should I go from here? Please help so I can finally enjoy my first bike!

[loud et]

The video links are not working for me. You may have to use photobucket or the like.

[7981GS]

I'm starting to get frustrated but I know you all will be able to help me out, I've learned so much already.

It's an 81650G with 14k on the clock just picked her up. Things I've noticed:

White smoke out of the left pipe only
all plugs were fouled and smelled oily
at one point I think there was gas in the oil from petcock but only idled shortly like that
a lot of grime on upper breather house area (don't know if its just cause it's 30 years old)
choke is frozen
starts up fine.

Here are some videos:

http://www.facebook.com/ajax/flash/expand_inline.php?v=10150984781252951&target_div=unbh4n_116&playertype=permalink&max_width=403&max_height=403&context=timelineSingle

http://www.facebook.com/ajax/flash/expand_inline.php?v=10150984783222951&target_div=unbh4n_112&playertype=permalink&max_width=403&max_height=403&context=timelineSingle

second start up and rev:

http://www.facebook.com/ajax/flash/expand_inline.php?v=10150984785072951&target_div=unj4fn_97&playertype=permalink&max_width=403&max_height=403&context=timelineSingle

So far I've cleaned and oiled the filter which looked dirty
replaced the plugs with new ones (these videos are the first run with new plugs)
pulled the carbs and checked the floats and they weren't stuck. overall looked pretty clean.

Where should I go from here? Please help so I can finally enjoy my first bike!

Post the video's on Youtube so that we can see them?

Eric

[overboostin]

Sorry guys just fixed the videos. Should be good now

[BassCliff]

Hi,

It sounds like you have yet to complete all the necessary maintenance.

Note the following from your "mega-welcome":

***********Quoted from Mr. bwringer************
Every GS850 [and most other models] has (or had) a set of well-known issues that MUST be addressed before you have a solid baseline for further troubleshooting. It's a vintage bike, and it's quite common (as in, every single GS850 I have had contact with) that there are multiple problems that have crept up and slowly gotten worse over the years. It's not like a newer vehicle, where there's generally one problem at a time.

These common issues are:

1. Intake O-rings (install NEW OEM or Viton only - common nitrile O-rings will quickly deteriorate from heat)
2. Intake Boots (install NEW -- these cannot be repaired)
3. Valve clearances (more important than most people think)
4. Carb/airbox boots
5. Airbox sealing
6. Air filter sealing
7. Petcock (install a NEW one)
8. On '79 models, install new points or Dyna electronic ignition (or at least verify that the old points are working correctly)
9. On all models, it's fairly common to have problems with the spark plug caps. These are $3 or $4 each, and often worth replacing if you're keeping the stock coils/wires.
10. Stock exhaust with NO leaks or holes -- good seals at the head and at the junctions underneath.

What I have noticed at the rallies is that very, very few 850Gs are actually running right. Make VERY sure it's actually running the way it's supposed to before busting out the modifications.

Brian's E-Z and fun plan for GS850 happiness:

1) Seal the airbox and air filter with weatherstripping.

2) Ensure no intake leaks. Spraying WD-40 or water doesn't tell you much, since very small air leaks can cause problems even though they won't suck in enough WD-40 to make a difference. Replace your intake boot o-rings and boots if needed, and seriously consider spending the lousy $28 for new airbox/carb boots.

3) Ensure clean carbs with correct settings, new o-rings, and original OEM jets. No, not just squirted with something. I mean completely disassembled.

4) Check/adjust valve clearances (Manual calls for every 4,000 miles. This is not optional.)

5) Ensure healthy electrical system.

6) Seriously consider upgrading coils and plug wires.

7) Install new, stock NGK B8-ES plugs gapped to .031".

8 ) Fine-tune float height and idle mixture screw to ensure best off-idle transition.

9) Clean air filter and reinstall with only the lightest oil mist -- over-oiling and/or letting the filter get dirty is a common and critical mistake, and will make the bike run funny at low speeds and run rich. This may take a few tries.

10) Make sure the exhaust seals are sealing.

11) Ooh, much better now, huh? You're gonna need upgraded suspension - Progressive or better fork springs and shocks. Set suspension sag appropriately.

12) Upgrade brakes with new pads and stainless lines to deal with all that extra speed.

13) Install new petcock, since I'm going to head to the roof with a rifle if I have to read about yet another #2 plug fouling and failed hillbilly attempts to rebuild the petcock and/or deny there's a problem.

14) Oh yeah -- check compression somewhere in there to ensure the valves and rings are reasonably healthy.

15) You'll probably need new OEM clutch springs -- the clutches last forever, but the springs get tired after 20 years or so under pressure. E-Z and cheap.
************End Quote**************************

See the procedures on my website for properly cleaning/rebuilding your carbs. Everything starts with clean carbs, a tightly sealed air intake system, properly adjusted valves, and a clean electrical/charging system. Keep us informed.


Thank you for your indulgence,

BassCliff

[Nessism]

Yes, maintenance. Rebuild the carbs properly by replacing all the O-rings, replace O-rings on intake boots, vacuum sync, valve adjust, check the petcock, etc, etc, etc.

Do everything then ride the bike good and hard for several hundred miles after adding a few ounces of Marvel Mystery Oil to the gas. What you are trying to accomplish is make sure the rings aren't stuck in the pistons. After you run a few hundred miles than perform a compression or leak down test to test the rings and go from there.

[BassCliff]

Hi,

Yes, like Mr. Nessism, I also thought about the "stuck ring" scenario. Regardless, all of the maintenance must be done. Then you can ride the snot out of it. Usually a stuck ring will seal again and then you're good to go. But you won't be "good to go" if you neglect the rest of the maintenance. Keep us informed.


Thank you for your indulgence,

BassCliff

[overboostin]

Thanks for the help guys. I'm going to be ordering everything I need from cycleorings tomorrow and start everything on the list. For the stuck piston rings should I put the Marvel Mystery oil in the cylinder itself or just the gas tank? Since I'm not quite sure what cylinder has the possible frozen ring is there any harm in putting it in every one?

Thanks again.

[Rover]

Hello Overboostin,
I see you are somewhat local to me .If you are in North R.I. I would be happy to lend a hand with the valve adjustment or carb cleaning.
Andy

[overboostin]

Hello Overboostin,
I see you are somewhat local to me .If you are in North R.I. I would be happy to lend a hand with the valve adjustment or carb cleaning.
Andy

That would be awesome. I'm actually in Southern RI but I can bring the bike to you. For the valve adjustment can you buy shims individually locally around here? How much does it usually run?

[Rover]

That would be awesome. I'm actually in Southern RI but I can bring the bike to you. For the valve adjustment can you buy shims individually locally around here? How much does it usually run?

Three ways
This site has a shim club...check under services.
Z1 sells them
Also Eric is selling some 7981GS (parts for sale)

First step is to measure clearances and what shims are in the bike before you know what sizes to order.
Probably want to order a gasket,Boulivard Suzuki has free shipping today
Use "freeship" in the coupon space.

[Eric]

For the valve adjustment can you buy shims individually locally around here? How much does it usually run?

My local Suzuki dealer's service department swapped shims with me for free. Not sure how common that is, but it's definitely worth calling you local dealer to see what they have. It's definitely nice to have a local source, especially if you're like me and only have one bike and the weather's good.

[overboostin]

Finished up the MSF course yesterday and now I have my license! I tore down the carbs and cleaned and replaced all the gaskets and the gaskets for the intake boots. When tearing down the carbs I noticed two things:

Two of the pilot screws didn't have washers. I'm going to try and pick some new ones up today but how would the lack of them effect the running condition?

The choke bar that goes across the carbs didn't have a spring on it. I'll try and pick another one up today. My choke cable seems to be frozen too. Any good tips on loosening it?

I'm really excited to take my first ride today! Thanks again for all the help.

[thewiz]

Sometimes you have to dig those washers out, may be stuck in the bottom of the hole. Did you retreive all the springs also?

[overboostin]

Sometimes you have to dig those washers out, may be stuck in the bottom of the hole. Did you retreive all the springs also?

Yup I got all the springs. I checked all the holes with a flashlight and went fishing down there and they were empty.