Jdub goes there 1981 650e rebuild

[jdub6092]

Checked the valve tappet clearances again.
All were approximately the same as before with one interesting reading on intake #1.
In position A (cam lobe pointing up) I had the minimum .03 mm gap, but in position B, the gap was 0.10 mm.
None of the other valves had this discrepancy.
Also checked out the cylinder with a boroscope. Looks clean on the exhaust side but carbon is building up on the intake side, notably where the valve indent is located.

[jdub6092]

Beginning the paint process, starting with the front fender.
Started with two coats of Spraymax 2K epoxy primer, including the underside.
The Spraymax nozzle provides an excellent adjustable fan pattern, something I've never seen on a rattle can. The only negative thing about it is the can needs to be upright and fairly close to the part to get the best coverage. So the center part of the underside doesn't look great, but don't really care as long as it prevents rust.
However, I am really pleased with how the money side turned out.

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Will let dry overnight and fill in the dings in the morning if sufficiently hardened.

[jdub6092]

Almost as inevitable as death, taxes and GS stock regulators failing, are broken side cover studs on many bike brands.

I had a broken stud on the left side cover with a few spider cracks that appeared on the outside, but not too bad and only visible at close range.

There are dozens of suggestions on how to repair these depending on severity. This is what I settled on.

First I used a plastic welder with metal "staples" along and just beyond the cracks. Then filled in with melted plastic and smoothed out. Made sure to keep the area of stud separation clear of filler. I pressed some JB Weld Plastic Bonder over the repaired area and into the cracks on the outside.
After that it took me quite a while to settle on the method of reattaching the stud. I considered using the superglue and baking soda method, but that dried instantly and would not work well at the point of contact. Maybe I could use it for reinforcement after the stud was reattached.
I did a test and it dried hard as a rock, but seemed somewhat brittle. PVC glue also seemed like an option.

Then I saw how rock hard the Plastic Bonder over the repair areas was and it sanded like hard plastic as well.
So I went with the JB Plastic Bonder. Could not get a clamp to keep it in place, so I had to hold it down with both hands for about five minutes before I could let go.
Now that it is cured, it is quite strong. Just need to remember to pull the side cover straight out when removing and it should last a long time.

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A little messy, but I won't have to look at it.

[Griffin]

The GS650E side covers are much flimsier than the side covers on most other GS models. I dunno why, but they are.

Very prone to breaking. Mke sure you have soft grommets, that helps. Old hardened rubber is much more likely to cause a breakage.