Jdub goes there 1981 650e rebuild

[jdub6092]

Scrapped the video because the idle setting causes a stall after warm up and the hanging throttle has come back. Arggghhh.

[jdub6092]

Final photo montage

[rphillips]

Probably didn't matter but I failed to mention it said New Old Stock, with orig. package and the Suzuki part # sticker still attached.l

[Mr.humbucker]

Frame2.jpg
Frame degreased and washed. Have not decided on whether to send out for sandblasting and powder coat or sand it down partially and repaint myself.
I have some aircraft stripper standing by as well.
Any suggestions? Best bang for buck?

Again ... Costs a bit more but sand blasting and powder coating (mat black) is the way to go. I've done three GS models this way and I am very pleased with the results. The finish is very even, completely clean and durable. I've cleaned and painted a few but prefer the powder coating route.

[jdub6092]

Do you feel lucky??? parts diagram shows part # 45522-34500 for that rubber piece, gasket, or cushion, I just punched in Suzuki part # 45522-34500, on ebay, and found a new one that may fit. His description seems way off as there were no GS500 in "81" thru "83" but the part # pictured is correct and looks like a thick, or wide rubber piece that could go around a tail light. Noth'in to me, but could be worth a look .. I don't know why I do this, I've found a co. CMSNL.com that shows that part # fits the "81" & "82" GS650 and the "81", "82", & "83" GS500... Possibly other parts of the world got those GS500's but we didn't. .

I have checked ebay from time to time looking for parts that were missing or needed replacement. If i checked back enough it seemed like they would eventually show up. Looks like it happened again. Thanks for the heads up.
The only thing I still haven't found is the front master cylinder rebuild kit, but I got a cheap replacement MC that works just fine.

[rphillips]

Do you feel lucky??? parts diagram shows part # 45522-34500 for that rubber piece, gasket, or cushion, I just punched in Suzuki part # 45522-34500, on ebay, and found a new one that may fit. His description seems way off as there were no GS500 in "81" thru "83" but the part # pictured is correct and looks like a thick, or wide rubber piece that could go around a tail light. Noth'in to me, but could be worth a look .. I don't know why I do this, I've found a co. CMSNL.com that shows that part # fits the "81" & "82" GS650 and the "81", "82", & "83" GS500... Possibly other parts of the world got those GS500's but we didn't. .

[jdub6092]

The one awkward thing about the tail section is there is a huge gap around the tail light and I know there was a rubber piece that I think was glued in. Seeing how wide the gap is, it's hard to imagine how how thick this piece must have been to seal it and stay in place. Probably why I dont have it. Unobtanium as well.

[rphillips]

Remember just personal preference, the pre 1980 750's and 550's tail sections had noticeable style blended in. "78" GS1000 lost the style and looked more like a chopped off hunk of plastic, chopped off so they could poke a tail light underneath. In 1980 the 750's and 1100's were worse with the unstiled hunk of plastic with an odd looking tail light sticking out the back, then yours, they couldn't figure anything to do with the tail section so just started it at the rear of the seat then just sloped it off till it faded away into the abiss. Look at an old one then a newer one and see if you can imagine how much thought went into the early ones compared to the later ones... Dang never thought I'd be explaining my opinions of Suzuki tail sections.

[jdub6092]

Great job, looks great, you can be proud, CONGRATS... Now for my neg. views, since they first came to our showrooms, personally I've always thought, by far, the ugggliest tail sections ever on a bike... Again CONGRATS.

Thanks!
Ah, so you were a Suzuki dealer back in the day? So you would have had an eye for style.
Nothing special about the tail section, but I've seen a few others that look fairly similar. The 750 had a very similar rear cowl, but the tail light wasnt recessed. What would be an example of a bike with a really nice tail section?
I went to the dealer with two buddies back in 81. One bought the 650g and the other bought the 650gl. I thought about the g, but the gl was not for me.

[rphillips]

Great job, looks great, you can be proud, CONGRATS... Now for my neg. views, since they first came to our showrooms, personally I've always thought, by far, the ugggliest tail sections ever on a bike... Again CONGRATS.

[Grimly]

Another one saved from the Sawzall Bandits.

[jdub6092]

That's a FINE looking bike there! Congratulations!

Thanks Ed,

Your advice and tips have been huge in helping me get this done.

[jdub6092]

Another photo. Unfortunately it isn't riding season here. Been between 112°-118°F the last couple of weeks and it doesnt really cool down. Most I've done is start it up and ride around the neighborhood a few times.

[jdub6092]

About two years ago was trying to sell it during a garage clean up. Sent this picture to a potential buyer (free) and never heard from him.
That *@%^$*@%^$*@%^$*@%^$ed me off and I embarked on this journey with very little knowledge.

[Big Block]

Looks brand new, excellent work!