1983 Suzuki GS850 Cafe Racer Project

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.

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.

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.