New build 1980 gs850g aussie

[ged]

Put some parts back on her, whilst waiting for back order parts off Ashley Boulervard.

[ged]

Is this part right? PO had cut off frame where yellow lines are, to fit a 4 into 1 exhaust. I had an engineer weld up the frame to what I thought was back to original including the threaded muffler attachment. When I fitted the swing arm the part circled in blue has about a 2mm clearance when the shock is at full extension. (cheap shocks off ebay will refurb originals) Would this clearance be correct and that the swingarm would not drop any lower without hitting the side of the frame?

[Guest]

Mate that's lookin' real nice! Not sure on your clearance issue but I do recall seeing people posting similar looking clearance shots on here asking for clarification before, but I'm not sure if that means it's right... hopefully someone with an 850 can chime in and clarify for you...

[rustybronco]

Sorry ged, I was going to look at my 850 before I left for work this morning*. unfortunately it's hard to remember things after only getting a few hours of sleep. I can look at the clearance tonight if you need me to.

[chuck hahn]

Ged...you may want to order a new oring that goes between the halves on this rear diff I am sending. Its already split, so replacing it will insure its not gonna leak for many moons. And this may add some bling to the guages...Even though the listing has ended..send him a message and see if they have or can make more..

http://www.ebay.com/itm/SUZUKI-GS400-GS550-GS750-GS850-GS1000-CONSOLE-RESTORATION-DECAL-SET-/200666080610?pt=UK_Motorcycle_Parts&hash=item2eb8a16562

[Johno]

Is this part right? PO had cut off frame where yellow lines are, to fit a 4 into 1 exhaust. I had an engineer weld up the frame to what I thought was back to original including the threaded muffler attachment. When I fitted the swing arm the part circled in blue has about a 2mm clearance when the shock is at full extension. (cheap shocks off ebay will refurb originals) Would this clearance be correct and that the swingarm would not drop any lower without hitting the side of the frame?

I have similar clearance on my '81 GS1000G. Bike is as out of the factory.

[ged]

I have similar clearance on my '81 GS1000G. Bike is as out of the factory.

Thanks Johno your info has put my mind at ease

Ged...you may want to order a new oring that goes between the halves on this rear diff I am sending. Its already split, so replacing it will insure its not gonna leak for many moons. And this may add some bling to the guages...Even though the listing has ended..send him a message and see if they have or can make more..
http://www.ebay.com/itm/SUZUKI-GS400...item2eb8a16562

Chuck are you talking about an oring or is it a seal. I cannot remember what it looked like when I split mine, whether it was attached to the inside or outside piece. I have since replaced both pieces with all the bolts. I did read about putting sealant around a certain part when reattaching to avoid oil leak, I will have to find it again in the manual.

Those decals look great chuck will keep them in mind.

Sorry ged, I was going to look at my 850 before I left for work this morning*. unfortunately it's hard to remember things after only getting a few hours of sleep. I can look at the clearance tonight if you need me to.

Thanks Rustybronco, Johno has confirmed clearance is good.

Mate that's lookin' real nice! Not sure on your clearance issue but I do recall seeing people posting similar looking clearance shots on here asking for clarification before, but I'm not sure if that means it's right... hopefully someone with an 850 can chime in and clarify for you...

Thanks pete, it was a bit of a worry but all is sweet now. Have just sent payment off to Chuck Hahn in Texas for a pumkin and spline to finish off rear end.

[mike-s]

This is how i fixed that when i put longer rear shocks on my bike


Though you shouldn't have a problem with stock suspension when your bouncing down the potholed filled back roads, Unless there is something seriously wrong with your frame it should never touch as long as they don't with zero load on the shocks.

Just remember that with the bike's weight on them there will be a little more clearance, and when you are on it and stationary there should be significantly more.

[ged]

Thanks Chuck, got the 2nd parcel today Tuesday 31/1/12. Everything looks good and just waiting to put them together. Can you tell me if the spline you sent me is the gold one. I find its hard to tell and can never remember the difference between the three.

[ged]

This is how i fixed that when i put longer rear shocks on my bike


Though you shouldn't have a problem with stock suspension when your bouncing down the potholed filled back roads, Unless there is something seriously wrong with your frame it should never touch as long as they don't with zero load on the shocks.

Just remember that with the bike's weight on them there will be a little more clearance, and when you are on it and stationary there should be significantly more.

Thanks Mike-s looks pretty drastic measures but should work. Too late with mine already powdercoated.

[ged]

Thanks Chuck Hahn my pumkin from texas has arrived and is fitted. Didnt have to do a thing, nice and clean and shiny. Have not put any oil in it yet but looks good. New spline fitted and away she goes.

[Guest]

Nice work Greg! Shouldn't be too far off a roller again now?

And I see in the background why you're thinking of a Tranzac system

[ged]

Ok working on engine. Strip down a bit dirty.





Took valve cover off and found 4 strange circles on top of cover. Strange like UFO's.







Then found a broken off bolt holding the cam bearing cover. Only 1 bolt was found broken off and PO appeared to have left it. Does not seem to have affected anything with the missing bolt, I hope........
I then tried to drill it out, I got off line a bit with a slight angle but can get another bolt in there after tapping another thread. Bit rough but I think it will hold.



Took head and barrels to get bead blasted. The guy said no worries will not glass bead around cam area, sure enough glass beaded everything. I have used 1200 grit paper and smoothed out cam bearing holders and valve cup guides. Lots and lots of fine glass bead everwhere. I have washed the parts down 3 times with soapy water, pressure cleaner and then compressed air. Hopefully I have got it clean, will find out when its put back together, will be a very nervous time.










I used the VHT engine paint universal aluminium to spray the cam cover, head and barrels. Put them in my BBQ and cooked them to 150C for 30mins hope that right. Anyway the cam cover came out gold coloured I think it was over the grill part where alot of oil smoke burnt off and changed the colour. I have since resprayed and recooked part, now is the right colour.

Now in the process of painting the rest of the engine.

[Guest]

Looking good Greg! Hopefully that thread repair sorts it out.

I know it's a bit late but I got my cylinders and head wet blasted by a fella in Jimboomba.

Non abrasive so he did everything and not one journal or bearing face or anything was harmed and the finish is awesome. No paint required and if you get grease on it, it literally wipes straight off... even after the engine's been running with it on... all my weeping from the dodgy Athena valve cover gasket is gone after the first wash.

Anyway, looks like you got a good job done with the paint, she's really gonna look the part

Lookin' like you should be done in time for the next GSR run too!

[chuck hahn]

Looks good on there Greg...I got a line on a center stand i think...will let you know when I confirm.