82 850GL Resto...here we go

[downsy]

Greetings from down under , I am enjoying your rebuild soapy with pictures very much
Reminds me how much hard work it is to pull the thing apart, and even harder to put it back together, always have some bolts left over !
Well done on the job so far and look forward to your future episodes

[pete]

Mate that's looking nice and clean

[Good Times]

Here's the next episode Downsy:

I had about an hour and a half tonight to break out the simple green again. My daughter and I hit it for a little while and had a good time doing so, although she did tell me that the air compressor is too loud.

I removed the starter cover to find leaves around the starter and the space behind the starter. Not that big of a deal other than the fact that I had the number one carb leaking down onto those leaves which were stuffed around the wiring. Smokey the bear always told me that "only I could prevent forest fires" and here I am about to start one.

Here's what it looked like before we started cleaning:



Once I blew the leaves out I found these in there as well. I am pretty meticulous about labeling every part that comes off so I'm not left with extra parts when I'm finished, but what do you do when you find parts buried under leaves on the crankcase? No fair!

I found these under the leaves. Socket and bolt. They've been there a long time. The socket is packed with grease and grime.



I removed the stator. It's fried. Then fashioned a plug for the starter hole in the case. That will allow me to clean without getting water in the crankcase.

This looked pretty good:



Before:



After:



We're getting there slowly but surely. I've got to start making a parts list. Lot's of little things that I need to remember when I go to purchase parts.

I'll be back at it tomorrow for a little while. Until then...

These are the days of our lives.

[downsy]

Thanks goodtimes very enjoyable don't you just love the things you find when you start pulling these old bikes apart !
I look forward to tomorrows episode !

[Good Times]

More scrubbing.....

Started on the front of the motor today, the toughest part. The tach drive had been leaking for a while and all of that oil was baked onto the front of the motor.

Before (picture doesn't do it justice, it was nasty):



After:



I used up a lot of elbow grease today. It's still not like I want it but I am chipping away at it.

Pretty sore from all the scrubbing. I dropped my spoon full of stew tonight on the table at dinner. Everyone thought that was pretty funny.

[downsy]

It's hard work cleaning of all that baked on crud ! Looking good !

[brslk]

More scrubbing.....

Started on the front of the motor today, the toughest part. The tach drive had been leaking for a while and all of that oil was baked onto the front of the motor.

Before (picture doesn't do it justice, it was nasty):



After:



I used up a lot of elbow grease today. It's still not like I want it but I am chipping away at it.

Pretty sore from all the scrubbing. I dropped my spoon full of stew tonight on the table at dinner. Everyone thought that was pretty funny.

That before pic looks a lot like mine looks. Did you fix the tach drive leak?

Bruce.

[Good Times]

I haven't fixed it yet. I have the oil band and sleeve but am planning on replacing the case gaskets and fix the tach before I paint it. Just trying to get it clean so I can paint it later. I think I'm about to try some paint stripperr on the motor next. I'd like to get it as close to metal as I can.

[Good Times]

Still at it! I've just been posting up in the other forums to tackle some issues. Here's everything in a nutshell.

http://www.thegsresources.com/_forum/showthread.php?t=187350

http://www.thegsresources.com/_forum/showthread.php?t=187537

In the meantime I fixed the tach drive and received this in the mail and will be putting that to good use as soon as I locate the right material to plug my ports.

[Good Times]

I think I have her all sealed up and ready for soda blasting tomorrow. Lots of trial and error on finding plugs for the ports. I finally bit the bullet and bought the test plugs. I bought 4 and plan on blasting the exhaust side with them in with the intake ports taped and then switch them when I blast the intake side. I'll have to clean up before the switch, but those plugs aren't cheap.



Sheetrock anchor wrapped in electrical tape. Tapped it in then put the screw in.


Ready to go!

[brslk]

Very interested to see how this works out. If you don't mind my asking, how much were those plugs and where can they be purchased?

Bruce.

[Good Times]

I bought them at Lowes for about $4.50 each. I had to modify/grind the base piece of plastic to make it fit in the port, but that was no big deal. There is no doubt that they are all sealed up.

They are called test plugs and I got them in the plumbing section. They come in different sizes.

This is the closest I could find online:

http://www.amazon.com/Jones-Stephens-Corp-T31-002-Stopper/dp/B000DZGLN2/ref=sr_1_7?s=hi&ie=UTF8&qid=1327932058&sr=1-7

Not sure what the base is made of though.

[Good Times]

This puppy is ready for primer and paint. Soda blasting worked.



I'll work on getting the covers polished, valve clearances into spec, gaskets, intake boots and stator replaced.

Then it's on to the frame and misc part for powder coat.

Then all the other stuff......

I made a big mistake on Saturday. I actually made a parts list and added the costs up for the motor. Dang it. Shouldn't have done that. I'm in too deep now though.

[brslk]

Looks great and gives me hope for my ugly oil baked on engine.
I'm gonna check out the local hardware store for those plugs tomorrow if I get the time.

Bruce.

[Good Times]

I have to get some parts ordered, gaskets replaced and two more shims in before I'm ready to paint. Need to wait for better weather as well.

In the mean time I've been working on polishing. Takes a while to get it right. My parts are pretty scratched and nicked up. Lots of prep work before the wheel hits them. Lots of redo as well. Spent most of the day on one part today.

Some before:



Some after: (Ignition cover is mid process)