82 850GL Resto...here we go

[Good Times]

Unfortunately,,,,,I have not, but it's winter time, bike is parked in the garage, I will get to it back in the spring and try to figure it out.....

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You'll get it GK. Old metal needs special attention. Especially in my case!

[Good Times]

Ok, so after the bike sat up a couple of months I now have a list of Spring Spruce up items:

1) Fix leak in front tire.
2) Rebuild rear caliper. (stepped on the rear brake and a stream of fluid came out of the caliper)
3) Replace oil pan drain plug. Gotta get a self-tapping over-sized plug.
4) Adjust rear brake light switch. It's sticking.
5) Replace broken windshield.
6) Change oil and filter.
7) Clean pods.

Woo-hoo!!!

[Good Times]

Ok, so after some parts coming in I got to work on the Suzi tonight.

1) Rebuilt the rear caliper. New seals, dust covers, pistons.
2) Bled the brakes.
3) Fixed the front brake light switch that was "sticking on".
4) Changed the oil, filter and o-ring.
5) Put the header back on with a little anti-seize on the SS Alan bolts.
6) Put the tank cushion on that was removed by a PO.
7) Replaced my breather tube with the addition of a spiffy new chrome breather filter on the end that no one will ever see. It's right next to my polished carb caps and breather cap that no one ever sees either.

Things I learned:

1) When ordering a set of pistons for the rear brakes don't order the seals and dust covers separately. They come with the piston set from Suzuki.

2) There is a crush washer on the oil pan drain plug. The absence of which will cause a leak. I learned that was why mine dripped all last season.

3) After 45 minutes of fiddling with, adjusting and taking the front brake light switch off and putting it back on about ten times I realized that I put it on backwards last year. I have no idea how it actually worked, but it did, until now when the light seemed to be stuck on. The wires face the BACK of the bike, not the front. I blew two fuses during this process because I had the ignition on while "adjusting" the switch.

4) Feeling a sense of accomplishment after doing all of these things can quickly turn when you back the bike out of the garage, turn the key, choke it and listen to it turn over for a while without starting.

So next on my list is to figure out what I did to the bike this afternoon to make it not want to start. It has started without hesitation up until two weeks ago when I took the caliper off and ordered parts. Hmmmm......

[Good Times]

It's amazing what walking away and getting some sleep will do. The first thought that came to mind was that I ALSO adjusted the throttle cable last night. Derr.... That's probably why it isn't starting.

[GateKeeper]

He GT, hope you get her sorted out.....I am going to venture into the garage today and see if my baby will start, been sitting in slumber for months now, and we have some nice weather today, I will just hope for a nice start, don't even have to ride yet, just the purrrr of the engine will put a smile on my face....

.

[wally]

So? Did it start? It's amazing the amount of (sometimes) silly things you learn by trial and error!

[Good Times]

Morning Report

Ok, so I adjusted this and she started right up:



Then I noticed this on the rear tire. Frustrated me:





New pistons and seals and I have the same leak. It's coming from the inside part of the caliper. I'll have to take it off to see where the leak actually is.

[eil]

If your calipers are the same as mine, they are two halves. Between the two halves is a rubber seal for the brake fluid passage. Did yours maybe get smooshed putting them back together? I replaced mine with a new one when rebuilding my rear calipers, and I seem to remember that I bought it separately.

[Good Times]

Thanks Eil. That seal actually came with the set and I was careful to put it back correctly. Of course that doesn't mean it didn't get kinked up or move some. That is the first thing I will check.

Right now GS = Get Some more parts. Ha!

If it's the piston leaking I'm not sure what else to do other than replace the caliper. I really don't want to do that.

[Good Times]

So far, so good. I have to dedicate this fix to Steve and Agemax. It's good to have brothers in arms when wrenching on the bike.

http://www.thegsresources.com/_forum/showthread.php?t=206407

I did not adequately clean the grooves in the caliper seals before installing the new seals. So I took my trusty wire wheel on the Dremel and did a proper cleaning. I cleaned them previously, but when I hit it with the wheel I saw that there was a lot of residue left in the grooves. I hit the flat surfaces and the seal surfaces between the two halves as well.

Bled the brakes. Tightened everything down. Pumped the brakes hard and, so far, no leaks. I even rode it around the block once.

Now if I can only find one of the rubber bleeder caps that I took off. LOL! (EDIT: Found it!)

http://www.youtube.com/watch?v=cSICoacOT60

[Good Times]

After a trip over Spring Break and cold weather finally passing, I got out and rode yesterday on my birthday. My wife bought me a new wind shield as a gift so I rode in comfort!

I had a few minor adjustments to make to the mirrors and throttle cable after installing the new Slipstreamer Spitfire and this it was back on the road for some fresh ethanol free gas and a short ride. Beautiful 75 degree day. The bike ran good and I am now back in the saddle!

[GateKeeper]

Good to hear your back on the road and in the saddle....way to go....

I was out today, and just my luck I got back to the house just as the rain started, got only a few drops on me and the bike, but even the 10 minute rides are great....

Hopefully we have a good riding season....

I got one bike to ride and one to wrench on....wooohoooo

.

[Good Times]

I got one bike to ride and one to wrench on....wooohoooo

.

You're livin the dream GK.

[Paul]

Hey a great restoration, I only managed to scan through it for now, but when I get going in May I'll refer back to it lots.... You set the bar very high there, I'm not sure I'll achieve the same detail as you, but I guess it will depend on what problems I hit along the way...Very Inspiring!! Cheers Paul

[Good Times]

Thanks Paul. Just saw your post. Inch by inch and you can do what I did and more. I appreciate the encouragement.

I am LOVING riding my bike and getting it a little dirtier than what you see in the pictures. It'll clean right back up!

I just need paint for the tank and side panels and ceramic coating on the exhaust and she will be complete. That will happen later.