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Thread: 1983 GS850G Rebuild Complete!

  1. #1
    Join Date
    Jan 2021
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    Default 1983 GS850G Rebuild Complete!

    Hey all, I've made a few posts to date on this project I've been doing, and I finally completed it last weekend! Aside from a couple of smaller issues that remain to be sorted out, It runs great and looks pretty good doing it.
    I'm going to throw a few pictures in here and then at the bottom I'll throw together a list of everything I remember doing/new parts that went on. Hope you enjoy!






    List of rebuilt stuff/parts in no particular order
    -replaced stator
    -replaced rectifier/regulator
    -rebuilt carbs (still giving me a little trouble with leaks while petcock is set to anything besides on, no idea why)
    -new petcock
    -new fuel line
    -replaced factory bars with a set from TCbros that are a little more comfortable and stylish
    -2 stage paint job done myself (if this wasn't already apparent from orange peel)
    -repainted calipers
    -new caliper pistons and seals on front and rear
    -Installed full OHA stainless brakeline kit
    -repainted parts of frame
    -new tach cable
    -replaced valve shims and corrected clearances
    -new valve cover, cam cap seals, and breather gasket from Realgaskets out of Tennessee (highly recommend them)
    -new fuel cap as the old one had a bad tumbler and wouldn't seal righ
    -repainted cylinder head
    -new hella horns (work intermittently, very loud when they do, might be a grounding issue?)
    -new throttle cable
    -new front master brake cylinder
    -Biltwell thruster grips
    -new fork seals and dust cap, went with 15 weight fork oil
    -new carb boots
    -countless hours spent cleaning chrome and metal parts with citric acid
    -new tires front and rear (rear was 17 years old, yikes.)
    -EBC organic pads on the front, semi-sintered on the rear.
    -Oil change
    -Final drive oil change
    -new battery

    I think that's most of it, but I'm sure there's a couple I missed. Bike runs great, just need to sort out the manageable but annoying issues with the carbs, get the last of the air out of the front brake lines, and figure out why on earth the tach cable is whining.
    Fun, long, frustrating, rewarding project. Just waiting for a nice day to take it on it's maiden voyage through the Minnesota River valley.
    '83 Suzuki GS850G
    Minnesota

  2. #2
    Gorminrider is offline Forum Sage Past Site Supporter
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    I'm not going to read all that! I know it cost at least as much as the bike to do all that not counting the love lavished ...but I like your style- A really good look you have going

  3. #3
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    Impressive work Gn0hm. It's a beaute
    1979 GS850G, currently being rebuilt from the frame up. We shall see how that go's
    "The two most powerful warriors are patience and time" - Leo Tolstoy
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  4. #4
    bwringer's Avatar
    bwringer is offline Forum LongTimer Bard Award Winner
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    Nice!

    The '83 is the fastest year 850...
    1983 GS850G, Cosmos Blue.
    2005 KLR685, Aztec Pink - Turd II.3, the ReReReTurdening
    2015 Yamaha FJ-09, Magma Red Power Corrupts...
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  5. #5
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    Congrats!
    That a huge list of repairs and replacements.
    You deserve a trouble-free summer of riding.
    2@ \'78 GS1000

  6. #6
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    Oct 2017
    Location
    Milwaukee, WI
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    "rebuilt carbs (still giving me a little trouble with leaks while petcock is set to anything besides on, no idea why)"

    Where do you see the fuel dripping from? I had a similar issue after rebuilding my carbs (same CVs as yours) and I knew the float heights were correct and needle valves were good. Turned out to be leaking O-rings on the fuel distribution pipes between carbs 1&2 and also 3&4 (the pipe between 2&3 is where the fuel line attaches, no leak there). Fuel was dripping along the front steel rail that the carbs are attached to, looked like it was seeping from the tops of the float bowls but it wasn't. Kinda hard to see the leak source with the carbs on the bike.

    Great looking bike, well done!

  7. #7
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    Lots of TLC given to this bike. Great Job! I hope you figure out the carb situation. Enjoy your riding year.

    Ed
    GS750TZ V&H/4-1, Progressive Shocks, Rebuilt MC/braided line, Tarozzi Stabilizer[Seq#2312]
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  8. #8
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    Minneapolis, Minnesota
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    Quote Originally Posted by Gorminrider View Post
    I'm not going to read all that! I know it cost at least as much as the bike to do all that not counting the love lavished ...but I like your style- A really good look you have going
    Yeah, I realize the cost of parts I put in vs the cash value of the bike was probably not the most financially wise choice I could have made, but for me it was about the rebuild and the time I got to spend with my dad working on it. Also the bike was so inexpensive for being as complete as it was when I picked it up ($300 USD) off craigslist that I figure I had a little headroom because of that.
    '83 Suzuki GS850G
    Minnesota

  9. #9
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    Quote Originally Posted by DucatiDave View Post
    "rebuilt carbs (still giving me a little trouble with leaks while petcock is set to anything besides on, no idea why)"

    Where do you see the fuel dripping from? I had a similar issue after rebuilding my carbs (same CVs as yours) and I knew the float heights were correct and needle valves were good. Turned out to be leaking O-rings on the fuel distribution pipes between carbs 1&2 and also 3&4 (the pipe between 2&3 is where the fuel line attaches, no leak there). Fuel was dripping along the front steel rail that the carbs are attached to, looked like it was seeping from the tops of the float bowls but it wasn't. Kinda hard to see the leak source with the carbs on the bike.

    Great looking bike, well done!
    That actually sounds like it might be the problem. dripping from the front, seemingly off of 1&4, I just can't piece together why it's only sometimes. Doesn't happen when the bike is off and the petcock set to on, which I figure is because there's no vacuum then. Didn't happen while the bike was riding with the fuel set to on, but did happen with prime, and also reserve at idle.
    '83 Suzuki GS850G
    Minnesota

  10. #10
    bonanzadave's Avatar
    bonanzadave is offline Forum Guru Past Site Supporter
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    Nice ride ! Hope to see you on the road.....

    Mpls ? Looks like the farm country.

    maiden voyage through the Minnesota River valley.

    Where you gonna ride that beast ?
    Last edited by bonanzadave; 04-25-2021 at 11:37 AM.
    82 1100 EZ (red)

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