82 850GL Resto...here we go

So far, so good. I have to dedicate this fix to Steve and Agemax. It's good to have brothers in arms when wrenching on the bike.

http://www.thegsresources.com/_forum/showthread.php?t=206407

I did not adequately clean the grooves in the caliper seals before installing the new seals. So I took my trusty wire wheel on the Dremel and did a proper cleaning. I cleaned them previously, but when I hit it with the wheel I saw that there was a lot of residue left in the grooves. I hit the flat surfaces and the seal surfaces between the two halves as well.

Bled the brakes. Tightened everything down. Pumped the brakes hard and, so far, no leaks. I even rode it around the block once.

Now if I can only find one of the rubber bleeder caps that I took off. LOL! (EDIT: Found it!)

http://www.youtube.com/watch?v=cSICoacOT60

Thanks Eil. That seal actually came with the set and I was careful to put it back correctly. Of course that doesn't mean it didn't get kinked up or move some. That is the first thing I will check.

Right now GS = Get Some more parts. Ha!

If it's the piston leaking I'm not sure what else to do other than replace the caliper. I really don't want to do that.

[eil]

If your calipers are the same as mine, they are two halves. Between the two halves is a rubber seal for the brake fluid passage. Did yours maybe get smooshed putting them back together? I replaced mine with a new one when rebuilding my rear calipers, and I seem to remember that I bought it separately.

Morning Report

Ok, so I adjusted this and she started right up:



Then I noticed this on the rear tire. Frustrated me:





New pistons and seals and I have the same leak. It's coming from the inside part of the caliper. I'll have to take it off to see where the leak actually is.

So? Did it start? It's amazing the amount of (sometimes) silly things you learn by trial and error!

He GT, hope you get her sorted out.....I am going to venture into the garage today and see if my baby will start, been sitting in slumber for months now, and we have some nice weather today, I will just hope for a nice start, don't even have to ride yet, just the purrrr of the engine will put a smile on my face....

.

It's amazing what walking away and getting some sleep will do. The first thought that came to mind was that I ALSO adjusted the throttle cable last night. Derr.... That's probably why it isn't starting.

Ok, so after some parts coming in I got to work on the Suzi tonight.

1) Rebuilt the rear caliper. New seals, dust covers, pistons.
2) Bled the brakes.
3) Fixed the front brake light switch that was "sticking on".
4) Changed the oil, filter and o-ring.
5) Put the header back on with a little anti-seize on the SS Alan bolts.
6) Put the tank cushion on that was removed by a PO.
7) Replaced my breather tube with the addition of a spiffy new chrome breather filter on the end that no one will ever see. It's right next to my polished carb caps and breather cap that no one ever sees either.

Things I learned:

1) When ordering a set of pistons for the rear brakes don't order the seals and dust covers separately. They come with the piston set from Suzuki.

2) There is a crush washer on the oil pan drain plug. The absence of which will cause a leak. I learned that was why mine dripped all last season.

3) After 45 minutes of fiddling with, adjusting and taking the front brake light switch off and putting it back on about ten times I realized that I put it on backwards last year. I have no idea how it actually worked, but it did, until now when the light seemed to be stuck on. The wires face the BACK of the bike, not the front. I blew two fuses during this process because I had the ignition on while "adjusting" the switch.

4) Feeling a sense of accomplishment after doing all of these things can quickly turn when you back the bike out of the garage, turn the key, choke it and listen to it turn over for a while without starting.

So next on my list is to figure out what I did to the bike this afternoon to make it not want to start. It has started without hesitation up until two weeks ago when I took the caliper off and ordered parts. Hmmmm......

Ok, so after the bike sat up a couple of months I now have a list of Spring Spruce up items:

1) Fix leak in front tire.
2) Rebuild rear caliper. (stepped on the rear brake and a stream of fluid came out of the caliper)
3) Replace oil pan drain plug. Gotta get a self-tapping over-sized plug.
4) Adjust rear brake light switch. It's sticking.
5) Replace broken windshield.
6) Change oil and filter.
7) Clean pods.

Woo-hoo!!!

Unfortunately,,,,,I have not, but it's winter time, bike is parked in the garage, I will get to it back in the spring and try to figure it out.....

.

You'll get it GK. Old metal needs special attention. Especially in my case!

Me too GK! Had to laugh at myself a little. Time to pay the stupid tax.

Did you get your idle issues sorted?

Unfortunately,,,,,I have not, but it's winter time, bike is parked in the garage, I will get to it back in the spring and try to figure it out.....

.

[GSXR7ED]

Thanks to you too!

Thanks Ed. Glad you read the thread. I really enjoyed the process. I hope you enjoy your 82!

It's going to be a slow process but well worth it...seeing how your's turned out.

Sorry to hear about your glass shield thing.



Ed

[pete]

Bugger GT! I get so paranoid about the stands being down properly these days... I've had similar issues in the past with no damage thankfully.

Then today after picking the 450 up after 3 weeks without it, I stop in the city to pick something up and try to ride off with the disc lock still on the front disc... thankfully I only rolled forward enough to bump it against the caliper and wasn't actually accelerating...

Awwwwwwww man that SUCKS.....

Glad it was not worse

Me too GK! Had to laugh at myself a little. Time to pay the stupid tax.

Did you get your idle issues sorted?

Beautiful bike! I'm new here and just picked up a 1982 GS750TZ. Seeing the transformation was amazing! I actually went through every page, mostly looking at pitures and reading a little bit. Thanks for sharing your story.


Ed

Thanks Ed. Glad you read the thread. I really enjoyed the process. I hope you enjoy your 82!

[GSXR7ED]

Got a call from my trusty local bike shop and my windshield was in. Picked it up on the way home to lunch and wound up with my first attempt at placement.



It's raining here today so I can't ride yet. that will be the true test. I like the Spitfire. The idea is to have it knock some of the wind off first and second to match the lines of the bike.

I'll try this out configuration out first:

Beautiful bike! I'm new here and just picked up a 1982 GS750TZ. Seeing the transformation was amazing! I actually went through every page, mostly looking at pitures and reading a little bit. Thanks for sharing your story.


Ed