gs relay mod and shim measurements

[hardwareman]

Took the top off the motor while looking about the relay mod........can't get the feeler gauge under any valves!!!!My smallest is .032 and if I am looking at the valve right it will not fit under three and four.Have not tried the other side but yes,,the valves are too tight.No local shop has any shims in stock so tomorrow at the weekly meet will 'try to pry' a donor from the grasp of the gate keeper.Seems that almost noone adjusts these things and one shop advised me to not take the valve cover off anyway as they always leak when you do!!Checked for shims and they seem to range from 70.00 to 100.00 plus shipping.Seems a little steep for some stamped out hardened metal but they have a monopoly on a needed product soooooo.The gasket came off clean with no effort to remove the valve cover.If it goes back as easy as it came off then no problems mate.
the relay is another story.bOTH wires need to be jumped into??that feed the coils??under the frame is a relay looking devise with an orage wire with a tracer a green and a black.do I unplug this and feed into the orange??ND WHERE DOES THE WIRE FOR THE SWITCH GO?? as per the diagram.Bike looks clean around the connecters and as such I have not taken any wires loose.Is there a better picture of the conversion somewhere?70 degrees tomorrow so it would be nice to put it back and try it up on the dragon.Hopefully the task force assigned by the governor has not started for the year.They got pretty bad last year and I almost got a free ride downtown.He was checking everything .tires,mirrors,insurance,registration,looking for baffles and so I gave him a rubber out of my pack.'What's this for ?"' He asked.I told him ;If you are going to act like one,dress the part!''

[jabberjoe87]

what year and model gs is it? For my bike a 77 750 the shim clearance tolerance is .03- .08. The first time i checked this all out i scratched my head also. Everyone on this forum does valve adjustments, I just did one last weekend! CHeck out basscliffs website, he has alot of info on doing it. Its not a big deal at all. Just remember not to take all of the shims out at once and rotate the engine as the buckets will chew up the cam lobes

[hardwareman]

shims

1980 Gs1000e .16,000 miles and looks like the clearances were never adjusted.

[Nessism]

Valve adjust tutorial... http://members.dslextreme.com/users/...lve_adjust.pdf

[bwringer]

PLEASE make sure you are measuring millimeters and not inches. Please.

A set of metric feelers that go down to .03mm will run you about $9 at most motorcycle shops -- look for the "BikeMaster" brand.

It is common to find a lot of tight valves on neglected engines. They usually make it around 10,000 - 12,000 miles before they start running really crappy and get parked.

[hardwareman]

I weill check in the morning.They might be inches.Just bought them a harbor freight as mine could not be located.Measurements are .03 to .08 metric?

[Steve]

Measurements are .03 to .08 metric?

That's right. One reason everyone says to measure in metric is that metric is 0.03 to 0.08 mm and in inches, it's 0.001 to 0.003". See that "3" in both measurement systems? Problem is that in one system, it's the maximum measurement, in the other system it's the minimum. VERY important to keep track of which system you are using. Since the bikes were made with metric measurements, it only makes sense to measure them with metrics.

There is also no reason to spend that much money on a full shim kit. Just measure your clearances, record them, check your shim sizes, record them, see what you can move around. Chances are that you can re-use some of your shims in another location and only need to get a few shims. New shims are about $5.25 at Z1 Enterprises.

Speaking of recording clearances and shim sizes, send me an e-mail with a request and I will send you a copy of my Excel spreadsheet that will help you figure out what shims you will need and will keep track of your shim sizes from one adjustment to the next. Personally, I think it's a rather handy tool, and I think that most of the 184 people to whom I have already sent it will agree.

.

[chef1366]

http://members.dslextreme.com/users/bikecliff/images/coil_relay_mod.html

[smoothbomber23]

Get the spreadsheet, it makes life easier.

[BassCliff]

Greetings and Salutations!

Hi Mr. hardwareman,

A year ago you snuck your first post into someone else's thread. I responded to you with one of the early versions of the "mega-welcome". Just to remind you of all the information that's readily available, let me be a little redundant.

I think the main questions right now should be; Have you followed the carb cleaning bible religiously? Have you performed a bench sync the carbs? Did you put the airbox back on? Are there absolutely no leaks in the air intake system (i.e. new boots, o-rings, airbox sealed)? Let me roll out the welcome mat for you. Pay particular attention to the "Top 10 Common Issues".

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff