82 850GL Resto...here we go

[Sci85]

Nice start there GT. I was surprised to see you were able to get those deep gouges out. Good to see it can be done. I'm looking forward to seeing something nice and shiny soon :-)

After spending the morning cleaning the gasket/junk off the clutch and stator covers and draining the crankcase, the kids and I got back out in the garage this afternoon and evening.

Charlie started helping me sand the ignition cover but that devolved into him sitting in the boat with my helmet on pretending to be a race boat driver. Elizabeth was supervising us both while working on a beaded necklace for Mommy for Valentines day. Believe me, that was the most important work going on the the shop tonight! There was a lot of sparkling conversation the whole time between the three of us. Mom is out at dinner with the "girls" tonight. Prime refurb time.

Here's where I started this afternoon:


Got the oil window cleaned up on the clutch cover using simple green, tissue and a small flat head screw driver to move it around in the window. Glad I didn't buy a new one:


Then I got started on the stator cover. You can see that it wasn't in great shape:


Ground the gouges out of the cover:


Took the emblem off and hit it with some stripper to remove the glue:


Got to sanding and stopped here so I could get the kids down for the night:


I"ll pick up here tomorrow.

Excellent work and kudos on keeping it a stock refurb. Too much choppin goin on hereabouts . The big secret to restos is to pace yourself. Don't do too much all in one fell swoop and take a break every couple of days. If you push it you'll burn out.

The other bigger secret to restos is.....................don't ever total up the costs, you will bring on a coronary or if the boss finds out you'll be up on "divorce court" before you know it

Keep the pics coming. All these restos are getting me through the winter without jonesing too much for riding season.

Cheers,
spyug

PS Nice bonus too working with the helpers. Brings back warm memories of working with my old man at that age only his thing was sail boats. Memories to last a lifetime and maybe a lead into to a passion for them. Good stuff.

Thanks for the pep talk Spyug! Needed that. Got a little discouraged when I saw water in the crankcase this morning. After inspection I'm over that and moving along nicely.

You are correct. I have made both of those mistakes. Making a parts list and was tempted this morning to make a push here. I have been to my therapist and now am thinking correctly.

Take my time. Do it right. The result will be better both in the bike and how you feel about it.

I'm even thinking about polishing the oil pan since I've got it off the motor. Crazy, yes. But then again, I ride a motorcycle.


Note to self on the clutch cover disassembly: http://www.thegsresources.com/_forum...d.php?t=188055

Excellent work and kudos on keeping it a stock refurb. Too much choppin goin on hereabouts . The big secret to restos is to pace yourself. Don't do too much all in one fell swoop and take a break every couple of days. If you push it you'll burn out.

The other bigger secret to restos is.....................don't ever total up the costs, you will bring on a coronary or if the boss finds out you'll be up on "divorce court" before you know it

Keep the pics coming. All these restos are getting me through the winter without jonesing too much for riding season.

Cheers,
spyug

PS Nice bonus too working with the helpers. Brings back warm memories of working with my old man at that age only his thing was sail boats. Memories to last a lifetime and maybe a lead into to a passion for them. Good stuff.

Just got finished taking off the case covers to get them polished up. Noticed I got some water in the crankcase somehow from when I sprayed it off last time. So I pulled the oil pan to drain it and check for any damage. Things looked ok until I looked in the bottom of the oil pan.

duhn...duhn....duhhhhnn!

I noticed when I pulled the clutch cover off that there was no OEM gasket. No gasket at all as a matter of fact. A PO used some type of liquid gasket. Not good as evidenced by all of the junk in the oil pan. All kinds of "gasket" material that has been running around in my motor for who knows how long. Dang it.

Going to keep up with the refurb and clean it up as good as I can. Will be glad to get the new parts in and get this back together.

Put in a parts order. New cover gaskets all the way around, oil pan gasket, real gaskets for head cover and breather. New stator and ignition cover emblems. A few screws and bolts I need to replace. I also have a set of hex bolts coming in for the carbs once I tackle those.

Still working on valve clearances. I only have one more to get in spec. This has really been an adventure. The Shim Club has been a life saver. I would have spent over $100 easily on shims had I ordered what I needed. I've had to swap more than a few out trying to reach a baseline for my clearances. My #1 intake went from a 2.95 to a 2.50. Here's the rest of the story: http://www.thegsresources.com/_forum...84#post1581884

I'll order a new stator next. Get the motor painted. Cases polished. Get everything buttoned up on the motor. Then it's on to the rest of the bike.

[pete]

Man they're lookin' good! Nicely done

Thanks fellas!

I really appreciate the feedback. I got up this morning thinking I'd knock all the polishing on the cases out today. Ha! Not quite. It is worth it though to see that mirror finish. It'll look good when I get it all done.

Nice work....

as Daniel said, since you do such a nice job, I should have sent you my parts as well, would have saved me a lot of work.....

Wow!
Can I send you some of my parts?

Daniel

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)

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.

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.

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.

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.