1980 GS850G restoration advice

[spankster]

Morning group. New member here. I've just scored a 1980 GS850G with 14K original miles. It's completely trashed. It's been outside in the weather for 15 years unprotected. I had to use a shovel to dig her out. The gas tank and seat are completely disintegrated. There were several rodent nests all over the place. I bought it knowing full well that it might be at least a year before I could get her back on the road...maybe more. I've decided to do a mechanical restoration first, then worry about a cosmetic restoration if she runs good enough to warrant it. She ran great when she was parked, or so I was told.

What I'm looking for is advice from other GSers who have tackled similar projects. How far do I go? I'm thinking at the very least I need to pull the top end to examine the cylinders/pistons/rings...maybe a cylinder honing...but is it possible that I could get away without pulling the lower engine/transmission apart? I can see oil in the little indicator window, and it looks clean. The wiring doesn't look too bad....don't know about the electrical components yet. The tires are badly cracked, but they do hold air. Anyway, that's my tale. Any advice or links to good advice much appreciated. I'm guessing I will become a fixture here for the next couple of years. Very happy to find this resource!
Thanks!

[Suzuki_Don]

Sounds like you have taken on a huge task here SPANKSTER.

First of all WELCOME

Secondly have a look at BASSCLIFFS website, he is a regular member here and has collected a lot of useful information from the forums and elsewhere with the help of others. Have a read, I think you will find it really useful.

http://members.dslextreme.com/users/bikecliff/

These are some edited quotes from one of our dear beloved gurus, Mr. bwringer, with ideas on basic needs (depending on initial condition), parts, and accessories.

***********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.

Carburetor maintenance:

Replace the intake boot o-rings, and possibly the intake boots. Here's the procedure:
http://bwringer.com/gs/intakeorings.html
Here's an overview of what happens with this particular problem:
http://cycleorings.com/intake.html
You'll also want to examine the boots between the carbs and the airbox. There's a good chance these are OK, but check them over.
And finally, if things still aren't exactly right, you'll want to order a set of o-rings for BS carbs from the GS owner's best friend, Robert Barr:
http://cycleorings.com
Once you receive these rare rings of delight, then you'll want to thoroughly clean and rebuild your carburetors. Here are step-by-step instructions that make this simple:
http://thegsresources.com/gs_carbrebuild.htm

[rustybronco]

Good morning Spankster and welcome.

I would first like to ask you, how much money and how much time do you have to spend on it?

If it has been outside for fifteen years, EVERYTHING on the bike will need to be replaced or gone through; brakes, wiring, electrical controls, tires, battery, carbs, valve adjustment, ect.

The only question that now needs to be asked is, will the engine turn over?

[spankster]

Thank-you Don and Rustybronco for the replies!

Don...the links are very much appreciated! I will scope them out.

Rusty, Time is not an issue...I can stretch this out for years if I need to. For me, the process is it's own reward. As far as money goes, I figure if I stretch it out over time, the money won't sting me too bad. Don't know yet if the motor will turn over. There's no kick starter on this model, so I'm assuming I'll have to pull a side cover to gain access to a mainshaft nut of some sort?

[hikermikem]

The round cover on the right side is where you'll find the end of the crank...

I would suggest pulling all the plugs & squirting oil, PB Blaster, or Marvel Mystery oil in each cylinder first before turning her over.

I have an '82 850GL that I put back on the road last year after it sat for 15 yrs. Fortunately it was stored covered in a shed all that time & was in very nice condition.

Good luck with your project, lots of members here have restored bikes similar to yours so there's a lot of help/advice available here.

[rustybronco]

Remove the right hand side of the bikes signal generator cover (the one with the emblem) that has three bolts holding it on. remove them, remove the cover and turn it with a 19MM wrench.

if the engine will turn "720"* degrees or more, hook up jumper cables to the bikes battery cables and the othe end of them to a "non running" vehicle, put a screwdriver across the two large posts of the "bikes" starter solenoid, which is located located under the left side cover (the painted cover with gs850g on it).

do she spin?

I would suggest pulling all the plugs & squirting oil, PB Blaster, or Marvel Mystery oil in each cylinder first before turning her over.

Good point!

* two rotations...

[twr1776]

I would check and clean the electrical, change the oil/filter and then try the motor first. Since it has been sitting so long use some fogging oil or Marvel mystery oil in the upper cylinders and crank it over by hand a few times. They upper cylinders are no doubt bone dry. Look inside the oil fill hole to see if you have any visible rust on the inside of the crankcase. As long as the motor did not get any water in it you might be OK.

[man8woman]

Make sure you check the secondary gear box for water damage mine was full of water when I got it.
Good Luck and have fun.

[robertbarr]

but is it possible that I could get away without pulling the lower engine/transmission apart? I can see oil in the little indicator window, and it looks clean.

The bottom end should be fine. Most of what matters has been under oil all that time.

Anything else -- well, at least some of those valves were open during those years, so I'd expect some pretty advanced corrosion on the cylinder surfaces, so turning it over might not be the wisest move at this point, especially if you're going to pull it apart anyhow.

[Larry D]

Welcome !!

I like the idea of getting it mechanically sound as a first step. If you are willing to take the time to "do it right".....is there any other way really ?......I'd pop the top end and have a good look. Sitting a long time with water involved is probably not good. On the other hand, you may be fortunate enough to find everything in good shape. Worth a look in my view.

Got some pics of it ?

[BassCliff]

Greetings and Salutations!!

Hi Mr. spankster,

Yep, you'll find lots of GS850G lovin' on my website. Have a heaping helping!

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", the Carb Rebuild Series, and the Stator Papers. Now let me roll out the welcome mat for you...

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