1982 GS650GLZ Rides Again

[txgs650]

Found a 1982 GS650GLZ in friends barn this November and it had been there since 1989. Thanks to the info on this website-forum, bikecliff website, and chief1366 it is running again. I was able to take it for a 50 mile ride yesterday afternoon in sunny east texas. I still have a lot of cleanup to go on the bike and will post some pics soon. Below are the items I have completed.

cleaned tank (electrolysis) - worked great
repaired fuel sending unit - lots of rust
replaced petcock - rebuilding was useless
replaced fuel/vacuum hoses
installed additional fuel filter
overhauled carbs/bench synch carbs
replaced intake o-rings
replaced intake bolts with allen heads
replaced plugs
replaced air filter
rebuilt front and rear master clyinders
rebuilt front and rear brake cyinders
replaced front brake fluid
replaced rear brake fluid
replaced engine oil/filter/0-ring gasket - found full of oil&gas
replaced rear drive gear oil
put air in front forks
replaced mechanical advancer (old one had tabs to turn crank sheared off)
installed DynaS3-2 - I had to modify dynaS bracket to due to oil pressure switch in the way. I can show picture if anyone needs.
installed relay for improving voltage to coils - the coil orange/white wires connection to the orange/white wire from kill switch is above the carbs (i had to cut open wiring harness a long way to find!)
repaired tachometer cable

total cost so far $450!

Bike runs well but cold idle at 1500rp(looks like I set open to much on bench synch) hot idle is around 2000 and I cannot lower. I will lower when I synch carbs. I'll also check valve clearances after I put some more miles on the bike.


thanks again for the help!!

[Suzuki_Don]

Don't wait to do valve clearances. Do them as soon as you can. Not a big job. Straightforward really. Cliff has a good tutorial on his website which is easy to follow and you can PM STEVE for the spreadsheet to record the info required to do the shim changes. http://members.dslextreme.com/users/bikecliff/

[Steve]

... and you can PM STEVE for the spreadsheet to record the info required to do the shim changes.

Who ... ME???

Please, don't PM me for the spreadsheet, send an e-mail. I need to reply to an e-mail address so I can attach the Exel file.

.

[Suzuki_Don]

Sorry Steve. My bad. Senile decay I think they call it. I should have known better seeing as I have been through the process of receiving your spreadsheet a number of times. FO PA.

[scrapper]

I heard it was "old timers" not Senile decay but,that is when you forget to feed the dog.
not "alzheimers" that is when you forget that you have a dog.

[Suzuki_Don]

I heard it was "old timers" not Senile decay but,that is when you forget to feed the dog.
not "alzheimers" that is when you forget that you have a dog.

Yeah!! On that topic my wife always says to me "you forget to feed the dog, but you never forget to feed yourself".

Dont know what she means by that.

[chef1366]

My stock stuff is popping up all over the Nation!

[txgs650]

Pic of my project

Finally remembered to take a pic of my winter project. Just got finished adjusted the timing per chief1366 rec'm and it made a big difference in performance of the bike. This is my first GS and my first restoration project. I still need to adjust the valves and synch the carbs. Not to mention all the clean up and polishing I have to do.

[Larry D]

Highly recommend the valve adjustment. As you probably know, it's a regular maintenence issue and must be addressed. It also provides a "baseline" for the rest of the engine tuning. Maybe backbone is a better term, without the valves adjusted properly, tuning/syncing the carbs and other engine work is likely wasted.

[txgs650]

Thats my next project. I have already received the spreadsheet from steve and hopefully I can get that completed this week. It is worth it to buy the suzuki valve tool? Read about the zip tie method but my luck would have a tip of the zip tie cut off in the valve!

[Nessism]

Thats my next project. I have already received the spreadsheet from steve and hopefully I can get that completed this week. It is worth it to buy the suzuki valve tool? Read about the zip tie method but my luck would have a tip of the zip tie cut off in the valve!

Get the Motion Pro version of the tool - less than $20.

Worst part of doing the valve adjustment is getting off the old gasket. Good luck with that if the gasket is original.

[Steve]

Use the heavy-duty zip-ties that are about 12" long. They are thick enough to not get cut.

.

[Larry D]

Get the Motion Pro version of the tool - less than $20.

Worst part of doing the valve adjustment is getting off the old gasket. Good luck with that if the gasket is original.

That's the truth, getting that original gasket off was not fun. I just used a sharp wood chisel and was very careful not to drop any pieces into the engine or gouge the surface. It took about 2-3 hours with my favorite cold beverage and some good tunes on the radio. Luckily about half of the gasket came off with the cover which is much easier to handle than getting up underneath the frame.

[Fenixgoon]

Get the Motion Pro version of the tool - less than $20.

Worst part of doing the valve adjustment is getting off the old gasket. Good luck with that if the gasket is original.

ugh those gaskets are miserable. i did mine using a disposable blade for cutting tools. after that, i used sandpaper to smooth out the surface. it ended up quite clean hopefully i didn't throw too much dust everywhere though.

also, if you need more info on valve adjustment and removing the shims, see this video by Kerry Burton of gstwin.com - he does an excellent job of showing how to do the valve adjustments:

http://video.google.com/videoplay?docid=-2015554469142545363

i actually wasn't able to get my valves adjusted, so that's still on my list of things to do when i have the chance

[ny_redneck04]

i used the zip tie method and holycrap it was so easy and no one got splattered with oil.