1983 Suzuki GS850 Cafe Racer Project

[Dirty Deeds]

Hello,

I just found this forum, looks pretty solid.

I picked up a 1983 Suzuki GS850GL just over a month ago for $240. The bike hasn't run in over 6 years and has 74,000 kms on it.



Four hours later it looks like this.



Shooting for a look something like this, but with clip-on bars.






I removed the engine and started tearing it down. So far it looks pretty good inside. I received the parts I needed for the rebuild. I am now just waiting on the stainless allen bolt kit.

I figure that I am going to work with an all black paint scheme, black everything, but I will play with the finishes. For instance I am thinking a gloss metallic black for the engine casing, a flat black for the jugs and head, and a black wrinkle for the covers. All accented with stainless allen bolts.

Anyhow here are a few pics of the engine.

[Dirty Deeds]

Sorry for the lack of before, during and after pics as I get going, then think, crap need pics.

Carb cleaning and replaced the old rusty screws with stainless allen bolts. I also soda blasted the bodies.









I also modified the upper fork clamp.








Prepped and painted the valve cover in black pearl. All of the engine covers in black satin wrinkle. As well as the head and jugs in flat black.

[Dirty Deeds]

I'm glad I opened it up, check out the head gasket.






Cleaning up the head.








The cleaned, checked, and painted engine block.







Last week I got my stainless bolt kit, pod filters, and fork seals. Still waiting on the seat, I was hoping it would come last week. But it didn't. This is killing me!!!! I can't wait to start chopping the frame!!!!

Anyhow this past weekend disassembled the forks, cleaned them out, replaced the seals, and filled them up with new fork oil. I also started to prep the frame for paint. I installed the engine covers and piston rings.

Now for some bad news, as I was prepping the frame for paint, this included the swing arm. Something that made me think a little when I was tearing everything down, and did not think about again until today. When I removed the swing arm during the tear down, the drive shaft came off with the swing arm.

So today I took a closer look, it seems the threaded part of the output shaft is sheered right off. I didn't notice before as it is perfectly flush at the base. Now I have to find a "new" used pinion/output shaft.

Anyone know a good place to source one? I will try searching the classifieds here as well.

[Dirty Deeds]

Got my seat last Friday. Therefore I was able to advance a little.











I chopped and detabbed the frame. I still need to fabricate an electronics tray and weld it all together, and fit the seat properly, but I am happy I was able to get the project advancing again. Also I was able to find the pinion gear set and it's on it's way.

[jsandidge]

Looks good! I particularly like the job on the fork lowers. Also, sent you a pm about some parts you might be willing to part with.

[loud et]

Looks good! I particularly like the job on the fork lowers. Also, sent you a pm about some parts you might be willing to part with.

Shipping may be expensive since I see he used "Nettoyant de Carburatuer" to clean his carbs . Lol

[loud et]

Looks like a good project. All you can do is put a parts wanted ad here and search engine bay for someone parting out an engine for that output shaft.
Did things go a little off with the wrinkle paint?
The cam covers look good, but the larger engine covers look a bit weird. Did they not dry long enough before a second coat or is it the camera causing them to look like that?

[Dirty Deeds]

Looks good! I particularly like the job on the fork lowers. Also, sent you a pm about some parts you might be willing to part with.

Thanks. I will get in touch

Shipping may be expensive since I see he used "Nettoyant de Carburatuer" to clean his carbs . Lol

Shipping shouldn't be too bad, Canada / US isn't too costly as long as the weight is low.

Looks like a good project. All you can do is put a parts wanted ad here and search engine bay for someone parting out an engine for that output shaft.
Did things go a little off with the wrinkle paint?
The cam covers look good, but the larger engine covers look a bit weird. Did they not dry long enough before a second coat or is it the camera causing them to look like that?

Thanks. I already found the output shaft, so all is good there.

Yeah.....It said to apply 3 heavy coats, I think I applied 3 too heavy coats. Things actually started to slide off. First kick at the can with the wrinkle paint. Anyhow, strip and repaint, that's all.

[loud et]

Canada, I got ya. No shipping shouldn't be so bad. Lol I just noticed the can and had to make a joke. Haha
I have never used the wrinkle paint either. Just like all things, try and learn.
Keep this build pics coming!

[Weasel]

Nice project & progress. I just brought home a '78 GS750 that I hope to turn into a cafe racer.

[Dirty Deeds]

Thanks. Just focus and follow through, it's not so bad once you get going.

Canada, I got ya. No shipping shouldn't be so bad. Lol I just noticed the can and had to make a joke. Haha
I have never used the wrinkle paint either. Just like all things, try and learn.
Keep this build pics coming!

That's it, it didn't work this time, but I feel the second time the finish will be even better. I will keep the pics coming, thanks.

[Dirty Deeds]

Got some more work done on the weekend. Received my output shaft secondary drive, so I am really happy about that.

So here it is.













Next weekend I have my daughter, so no progress for the next two weeks. However, the following weekend should progress quite quickly as I will be starting to remount everything.

[one_civic]

you should put your location in your signature, there are a few of us "canucks" on this forum who may be close to where you are

[Dirty Deeds]

Will do, but what would be the benefits?

[Weasel]

Nice work on the frame DD. I'm a few steps behind you on my racer project. Just got the carb gaskets and o-rings in the mail. I've got a long weekend off work so I plan to get the carb rebuild complete at least. Still waiting on the oil and air filter. Might do a simple green scrub of the engine too.