79 GS850 - Shooting for cross country reliability on a college budget

[stain]

There are external gas tank repair kits you can buy at your local auto parts store. Just make sure the area is CLEAN and dry. I have used the permatex brand with some success. You can get this brand of repair kit at some ACE hardware staores also.

[resjudicata]

I've done a temporary fix of a tank by pushing JB Weld into the hole and working it in there really good. Obviously, you have to prep the surface really well. And, shoot the spot to be fixed with Brake Cleaner so that there will be no residue left.

So, did you check the float heights? What were the measurements and how did you go about measuring?

When did you put those plugs in? I'd grab some new plugs now so you can see what the carbs are doing now.

Chris

[Lunchbox88]

I've done a temporary fix of a tank by pushing JB Weld into the hole and working it in there really good. Obviously, you have to prep the surface really well. And, shoot the spot to be fixed with Brake Cleaner so that there will be no residue left.

So, did you check the float heights? What were the measurements and how did you go about measuring?

When did you put those plugs in? I'd grab some new plugs now so you can see what the carbs are doing now.

Chris

I used this "Magnum Gas Tank Repair" epoxy putty yesterday after cleaning that area up with a wire wheel and so far its not leaking. I have no idea how long it will last, but I am just hoping to make it back from my trip before it lets go.

Also the plus a brand new, I bought them about 3 weeks ago. Measurements for the floats were done with a mm ruler and clear tube was done as well. After I finely tuned the float heights the clear tube looked just a bit better then the pic I have below.

Heres what the repair looked like and the stuff I used.

[Lunchbox88]

Hey guys I'm Back! I know its been a while, but after I finished the 1000 mile journey I was getting the bike ready for, life kept me pretty busy. The trip was awesome, and definitely got me hooked. We spent about 4 days traveling down to and around Arkansas, spending the nights at spaces like Mount Magazine and Queen Wilhelmina state parks.

A few pictures from the trip:
My bike loaded out:


The views:






Good signs as well:


Once I got back I knew that my bike was low on power and a compression test of between 85-100psi on all cylinders proves it. So now that I have a few weeks of free time I figured it would be time for at least a top end rebuild. Ive already gotten the engine out and the top end off leaving just the rods in place. My questions kind of start here. Given the picture below do I need to split the cases for any reason? Can I wash any debris from the head removal out with kerosene? Would you suggest new pistons or just re-ring with new pins? Given the color of the valves it looks like they may have gotten a bit hot, what kind of course of action should I take to heighten the reliability of the bike when Im finished. I have a budget of about $1000 plus few hundred if necessary to get this thing back up and running. What do you think? Pics below: