Clouds GS650GL Restoration Project Mitch

[cloudbreakmd]

After much searching a brass brush should work? Or Simple Green and a tooth brush.

[grayskull]

just purchased 83 gs650gl

i have just started on my second rebuild.asweet 650gl,black and silver tank.9800 miles.it has been layed over on both sides.same time dont know.i am wondering one thing though. i think i have to clean the carbs.How does the daggum air box come off.Its not like my gs850,its easy.HELP PLEASE..also the people i got the bike from thought the starter was bad,wrong,the clutch saftey switch was bad.Good for me.I only give 200 bucks for the bike with a title.They were the 2nd owner of the bike to..If you have any insight on how to get the airbox off and the carbs that would be great..

[duaneage]

Engines are painted, duplicolor 1615 is a close match.

I have a lot of the parts you need, I'm cleaning a few up and I'll bring them down later this week. I have a left side cover, I'm surprised that G side cover fit the bike.

Do you need a lockset for this bike or were you able to get a key?

[cloudbreakmd]

Finally got the key today and was able to crank and hear bike run off of starting fluid. So far so good... Well except the coils on the bike are butchered into place and I have to sand and paint a lot of spots on the frame Oh and the carbs... Three screws stripped during attemped removal, one screw stripped by PO... And one broken jet set firmly into the carb bodies via the PO.



So today I ordered another set of carbs and will use my current ones for parts if needed. Also Duane is bringing me a care package of sorts tomorow. That should cover more or less all the other major parts I needed. Pics to follow.

[cloudbreakmd]

This should make Dave happy. Here are the replacement tins I ended up buying.

[Dave8338]

This should make Dave happy. Here are the replacement tins I ended up buying.

THAT, my friend, earns a standing ovation!

Was that a fleabay find? Nice job on the tank and side covers. Even the 650 emblems look to be in good shape! OK...I'll give you a pass on the bars as long as the tins stay in original color scheme!

[cloudbreakmd]

Yep got the set on ebay. I will be selling my other set cheaply soon enough. So if you know anyone who needs a clean tank in red I got it.

[cloudbreakmd]

This project is becoming frustrating. 3 broken jets discovered now that I have managed to get all the rusted and stripped screws off... Sighs. Okay I guess it's time to order 4 rebuild kits.



Apparently there is a difference in the 1981 switch in terms of wiring to the other years. Time to just order a new button.



My replacment carbs I bought on Fleabay were not as advertised. Also different from the 81 models... Surprise. I am asking for a refund. Guess I get to eat shipping twice. I sent the guy an email and am waiting for a response.



Now to figure out the best way to drown myself in a shallow puddle.

[duaneage]

Drowning is not permitted.

I'll call you today and we will sort this out.

Stay away from swimming pools.

[cloudbreakmd]

I have some more pics of the chaos I am faced with on this project.

[cloudbreakmd]

I had to forcibly remove the rear pads because the caliper was locked. Duane was nice enough to provide me a replacement for a very reasonable cost from the parts he is selling.

[cloudbreakmd]

Tank arrived dinged due to poor packaging . New forks are on sans pitting. Tomorrow morning the old tins are off to paint.

But here's a problem. The old fender does not fit the new forks?????? The holes on the old fender are too wide for the new forks. Same thing with the brake hose holder. Help?????

[cloudbreakmd]

The project... Earlier I had mentioned a broken jet but I am not sure if I had mentioned the other to broken jets I found inside...



I had ordered a set of "mount and go" carburetors, that were supposedly "professionally rebuilt." Yeah right. I pulled them apart to clean them before mounting them just in case. I'm glad I did. The diaphragms were shrunk, the butterflies were frozen and the carb bodies were actually damaged.



Needless to say, i did not use them. I ended up deciding to use the old set. They are in bad shape at the bottom; All of the jets are torn up from improper handling with the wrong size screwdriver by one or more of the prior owners.



I ordered four brand new rebuild kits that should arrive midweek this week. I also began to tackle some other parts of the bike. New forks were fitted (the old ones were pitted), a new headlight trim ring, a new fork logo, and some other bits you will see in the pics below. Some pics will be added later, such as the new forks and trim ring. New hardware still needs to be ordered and installed as well.

[cloudbreakmd]

[cloudbreakmd]

Oh and the gas tank and side panels... Yeah the replacement ones are not being used. Alex at New Impressions Autobody is handling my paint on this one. The replacement pieces I bought were damaged during shipment. I know that it may seem minor to most people but my OCD won't have any of it. So the original tins are out being redone. Sighs...