The sons new project 1980 gs850

[pete]

Bugger on the engine failure Greg, that's no good!

The rest is looking spot on though...

[ged]

looking really good

how much did the New brake lines from Rennsport cost and are the in stock or made to order??

Mate they were about $120 AUS for the four hoses. I think I went for the GS1000s sizes because of the shorter handlebars. I still have the sizes and end attachment directions if you want them.

[ged]

Bugger on the engine failure Greg, that's no good!

The rest is looking spot on though...

Thanks Pete I want to jump ahead and get to the engine failure. Will show some more of the rebuild prior to it first.

[pete]

Looks great Greg! Now about the engine failure

[ged]

Ok got it finished. Carbs had 117 main jets and the Vance & Hines exhaust instructions said to put 120 in. After I did this bike idled fine but had no mid or top end power. I then changed the mains to 122 and it felt a little bit better but still a delay in the power mid to tops. The spark plugs looked on the lean side. Valves were all checked and adjusted to spec. Carbs were sync. Pics of bike first.













I test rode it first and travelled about 6 klms. Then I told the son to have a ride and see what he thought. Got a phone call from son..........no I thought are you all right did you drop it? Story from son was carbs still playing up, he said he was going about 130klm/hr when bike rear wheel locked up, he then pulled clutch in and came to a stop. Tried to start bike wouldnt turn over. So I hooked the trailer on and collected bike, engine was seized would not turn over, we were both devastated. I didnt take too many photos of pulling it down to find the cause because how upset we were. When we took the valve cover off we found number 3 intake valve shim shattered. All the valve shim gaps were in spec, this shim was an aftermarket shim all the other shims were the old original suzuki looking shims. This one was a brand new aftermarket shim I had purchased off Z1 or a company in Aus that Pete had told me about. Cannot be sure which one. Now I have found another post about a shattered shim on this forum also an aftermarket.

http://www.thegsresources.com/_forum/showthread.php?t=219760

Can we talk about shims here, or do you think I should start up a seperate new topic under another forum section?

[GSX1000E]

That 850 is, without a doubt, the best looking 850 that I have ever seen!!
Now, how did the shim get shattered and what damage did it cause?

[pete]

Wow that's an odd one Greg, bugger! I haven't heard any issues with Precision Shims (the one in Melbourne) and I think most of my shims are from there. I'd be surprised if Z1 used dodgy shims too... maybe just bad luck?

If you read to the end of the other thread, it looks like he thinks the clearance may have opened up too much...

[ged]

Yeah I just dont know. Damage caused was a broken cam chain, broken cam chain guides front and rear, damage to cam lobe, looks like all the valves are bent from hitting tops of pistons, lucky no pistons damaged just marks. I am not sure about using these after market shims, the son has told me no shims unless original suzuki. Mechanic mate of his states he has seen it before with shims shattering, original shims have a edge around both sides and the aftermarket ones are straight edge. They just look different, cast maybe not forged?

[eil]

Wow, that's some terrible luck after all the work you did. That bike is truly gorgeous!

Shattered shims are not terribly common, even aftermarket ones. That thread you linked to, we already know the root cause there: the guy over-revved the engine which caused the shim to exit the bucket and get mangled up in the valve train. So I'm not sure that one counts as evidence of a bad batch of aftermarket shims or such.

Regardless, hope to see this one back on the road soon.

[pete]

I had a look at Mick Hone's web site Greg, genuine shims are $14.85 each, Precision Shims are $9.95 each... I'm going to be ordering some very soon ready for the next service (pretty sure my exhaust clearances are lower than I like) so I might go genuine this time seeing as there's less than $5 difference!

[ged]

I purchased a couple of shims from Mic Hone thinking they would be genuine parts, but no they were aftermarket square edged shims like the ones from Precision Shims.

Anyway more problems, I was playing with the rings on a piston that felt abit tight and snap. Noooooooooooooo guess what no longer available .5mm oversize 12140-45121-050. Son is now whinging, dont want the bike anymore want a newer one. My answer was NO, get over it and wait.

Have put a request in the wanted section for anyone with any rings available.

[Joe H]

Hi, Just read thru your thread, what a heart breaker!
First class resto job, and great paint and decal work, all of the details where first class.
Best of luck getting on the road again, don't give up on that bike!

[sinkankan]

850 blessed are the rebuilders.

Very smart looking bike, well worth any more that you have to do to get it running sweet.
I've had some minor pricing issues with Mike Hones website, where the totals didn't add up to what was advertised. And when I complained and asked for a reason, I got a condescending email back saying "If you want the parts for free go somewhere else"
I don't care if he's got the last pair of gold plated nipple snappers on earth, I don't want to send him any business.
Picture of the wheels I did for my GS850, which by the way is going to the shop this weekend to get the gear change issue sorted out.

[pete]

That's interesting... I had a look through their parts fiche yesterday and going by that they have stock of Suzuki shims (about 3 of each size I checked) so that's odd that they supplied after market... I know they're not discontinued!

Did you call or order online?

There's two other places to try for your rings... Suziparts in SA (not cheap!) http://suziparts.com.au/ and Old Gold Motorcycles in NSW http://www.oldgoldmotorcycles.com.au/

Good luck mate!

[ged]

Hi, Just read thru your thread, what a heart breaker!
First class resto job, and great paint and decal work, all of the details where first class.
Best of luck getting on the road again, don't give up on that bike!

No I havent given up, son will get over it.

Very smart looking bike, well worth any more that you have to do to get it running sweet.
I've had some minor pricing issues with Mike Hones website, where the totals didn't add up to what was advertised. And when I complained and asked for a reason, I got a condescending email back saying "If you want the parts for free go somewhere else"
I don't care if he's got the last pair of gold plated nipple snappers on earth, I don't want to send him any business.
Picture of the wheels I did for my GS850, which by the way is going to the shop this weekend to get the gear change issue sorted out.

Thanks, Touch wood havent had any issues with Mic Hone except for the shims. Your wheels and bike looks great, whats the issue with the gear change?

That's interesting... I had a look through their parts fiche yesterday and going by that they have stock of Suzuki shims (about 3 of each size I checked) so that's odd that they supplied after market... I know they're not discontinued!

Did you call or order online?

There's two other places to try for your rings... Suziparts in SA (not cheap!) http://suziparts.com.au/ and Old Gold Motorcycles in NSW http://www.oldgoldmotorcycles.com.au/

Good luck mate!

Pete I ordered online through Mic Hone from the parts list thinking I was going to get original suzuki shims but instead got the aftermarket ones. I didnt call, just thought maybe the original ones are no longer available.

I just bought the last set of oversize rings in the world from www.classicsuzukiparts.nl looks like about $100 shipped here. Going to try and go back to original size, barrels, pistons and rings down the track.