1983 GS650 Rebuild.

[kws730]

I've started rebuilding my '83 GS650. I will upload pictures in a few days. Currently, everything is completely disassembled. I have painted the frame, engine, and brake calipers. I'm wanting to start reassembling the bike this week but i've run into a couple of Problems

1) I need new swingarm bearings. The ones on the bike were completely toast. chewed up beyond recognition. I have done some looking around (ie. bike-bandit.com) and I can't find a replacement. I contacted Suzuki and they said that the bearings have never been sold in North America. The part number on them is KOYO HC30202RRS. I have also contacted KOYO and they also said that it is not available in North America. Does anyone have any ideas on geting a replacement?

2) One of my headers is buggered. it has a hole right through both walls. Anyone have any suggestions for repair? i was just going to take them to a local exhaust shop and see what they can. But i would rather do it my self if i could.

Any tips or suggestions would be great. Again, i will upload pictures later this week.

[Guest]

S/A bearings

Right here: http://www.boulevardsuzuki.com/fiche...year=1983&fveh

(2) 09265-15003

[Suzuki_Don]

Those bearings are still available. Try Z1 Enterprises for a good price and quick delivery.

[kws730]

So apparently i can only upload one picture per post. This seems strange to me. so sorry for the large amounts of post coming on but i said i'd show some pics, so here it goes

First, the engine.



as you can see, need some lovin

[kws730]

And here's after some lovin



As you can see, this was done in the fall. before the snow. there's a good couple feet outside here now.

This reminds me the head gasket was completely toast when i opened the head to do some valve maintenance. Does anyone know the correct gasket material/thickness for a 1983 GS650???

[GateKeeper]

you can actually have 10 pictures per post, not just one

and in a larger format as well

how to is here - http://members.dslextreme.com/users/...t_pictures.pdf

[kws730]

And the next doing was the frame.

It was also in need on some through lovin. i'll skip the before since im having to do each pic in it's own post.

after many many hours, here's the result.



Looks not bad to me. All i have left to do to it is a clear coat then im free to get that engine back into it.

[kws730]

Well dont i feel like a fool for not using photo bucket. excuse the noobness of my posts. i dont often use forums.. . .. . until now

SO ANYWAY. here's the gas tank.



probably the worst interior rust i've seen. I used a kit from POR15 and it worked really well.




I even found some of the original paint!!! if the bike was that colour when i got it i would have left the paint. oh well. i'll end up repainting it black now




Though a little colour in the breaks would be nice. Black and Blue work...... right?



That about all i have pictures of right now. I'll upload a picture of my exhaust that needs repair, thanks to my tried to repair.......

If anyone knows how to fix a hole in headers please let me know.

By the way, thanks for the help finding a supplier for the swingarm bearings. I bought then and they'll be here by late this week.

[Nessism]

Photos look good.

Be sure to pop those caliper pistons out and clean out all the crud (sure to be) inside. You may as well do a complete job considering how far you've come so far.

[BigD_83]

Well dont i feel like a fool for not using photo bucket. excuse the noobness of my posts. i dont often use forums.. . .. . until now

SO ANYWAY. here's the gas tank.



probably the worst interior rust i've seen. I used a kit from POR15 and it worked really well.




I even found some of the original paint!!! if the bike was that colour when i got it i would have left the paint. oh well. i'll end up repainting it black now




Though a little colour in the breaks would be nice. Black and Blue work...... right?



That about all i have pictures of right now. I'll upload a picture of my exhaust that needs repair, thanks to my tried to repair.......

If anyone knows how to fix a hole in headers please let me know.

By the way, thanks for the help finding a supplier for the swingarm bearings. I bought then and they'll be here by late this week.

Is yours an "L" model? I'm just guessing from the colour of the tank, as all of the other '83 650Gs I have seen are black. Also, the Gs I've seen had the engine painted black as stock.

I covet your engine emblems. I've been searching for replacements of the black TDCC emblems for my '83 for awhile.

Which header has the hole, and how big is it?