1979 GS850 cleanup/rebuild

[Digitus]

Hello all, I'd like to start my own little project thread, some of my pictures and info is already in my introduction post, but its a bit strange to keep posting there to update pictures

I picked up a '79 GS850 recently and right now the bike is spread all over my garage

Things done so far:
- Took bike apart, frame and other black parts are off to be sandblasted/coated...black again of course.
- Checked the engine, good compression, no need to rebuild it completely yet
- Polished up engine parts, painted the valve cover
- Front forks polished, new seals, oil
- Brake calipers rebuilt, repainted rear brake caliper
- found a seat, 4-2 exhaust and front fender

Today I picked up a nice donor bike, guy who sold it said it would not "go"
it looks like someone left it outside for a long time...in the rain
Didnt have time to properly look at it.

I'll upload my pics to a google web album, so they will stay up for a long time..

https://picasaweb.google.com/marien.everse/GS850?authuser=0&feat=directlink

Todays pics:

 

[49er]

Interesting project. What type of shocks are fitted with the rubber spring covers?

That fairing looks quite decent too. It's the first one that I would consider fitting to mine, if I was that way inclined. Most large ones make a GS look geeky. Do you know what it came off?

looks like you scored well with the donor bike too. Keep documenting your progress.

 

[Digitus]

Interesting project. What type of shocks are fitted with the rubber spring covers?

That fairing looks quite decent too. It's the first one that I would consider fitting to mine, if I was that way inclined. Most large ones make a GS look geeky. Do you know what it came off?

looks like you scored well with the donor bike too. Keep documenting your progress.

Its standard shocks, the black covers were added later on as protection. They worked well, no damages that can rip a new seal. Unfortunately, they guided all the moisture inside the covers directly onto the spring that keeps the seal in place . Fairing is a Vetter Windjammer. Looks good on the outside, but cracked on the inside...got another one for free, cracked on the outside, looks good on the inside

I'll fix the bike without fairing first, so I can ride it...then make a wooden mount for the fairing and work on that as a separate project. Also looking for matching Vetter cases.

 

[Guest]

what type of exhaust is that? not the 4 into 1 but the shinny 2 into 1's that you have.

 

[Flaming Chainsaws]

what type of exhaust is that? not the 4 into 1 but the shinny 2 into 1's that you have.

It looks like a Motad exhaust!

You guys overseas got the much cooler paint jobs.

 

[Digitus]

what type of exhaust is that? not the 4 into 1 but the shinny 2 into 1's that you have.

its a BSM exhaust.. http://www.bsm-exhausts.com/images/prodsheet/4016.pdf

 

[Tim Tom]

Wow that in a nice looking engine. I also really like the seat on your donor bike. It's quite nice looking. I love my 850G and I'm glad to see one getting the attention it deserves!

I'll be following this build

 

[Flyboy]

I am along for the ride on this one to, having owned two 850's I have a soft spot for them, and agree, it is good to see this one getting the attention and care it deserves.

 

[Digitus]

Well, I managed to get the parts bike up and running...took 5 mins for a new battery and the choke wasnt working properly. Here's the Vid: http://www.youtube.com/watch?v=lKznPzDV21U It does not sound very healthy though...old gasoline, dirty carbs and whatnot. Im not going to ride that and trust my life to it

I like that seat too, its a bit sporty and has Suzuki name and logo fabricated into the seat...Brand is Giuliari .. made in Italy, name sounds familiar Underside is plastic, but cracked and repaired, but looks like a "quick repair"

Dont know how ppl know, but I already got someone whos asking for parts. Im a bit hesitant to sell parts right now, I dont want to sell and then come up short myself, that would be silly

Frame came back from the sandblast/coat company, looks good. Its some kind of special paint they also use on boats, very tough. sandblasting all parts, primer and topcoat was $150, not too bad I think.
Pictures:

 

[Digitus]

Hello Folks,

It was a busy week, work work work, but managed to do a few things.
Building up takes a lot of time and since this is my first serious project, I am amazed how quickly some of you work and how good some projects look.

here's the pic of the buildup so far... :dancing:

Have a good weekend !

 

[Digitus]

Well, im still waiting for some gaskets, but I am already thinking about putting the engine back into the frame...I said thinking, maybe I should say worrying...


Any tips on how to join frame and engine without breaking my back AND keep the coating on the frame undamaged?

 

[Digitus]

Hello all, I managed to do some things on the bike, when it was raining and other activities were put on hold... After much thinking I managed to put the engine back into the frame using straps and a motor lift. It worked great, I had to work slowly and check the clearance a lot, but I got it in without lifting it myself. :dancing:

Just when I thought I was quite a good mechanic I discovered that I forgot the rubber protection sleeve between the engine and the shaft :-s

Anyway, long story short: its 3:15 am now, everyone is asleep and finally I got my engine in properly WITH the rubber thingy
I just HAD to redo it and get it done before sleep

Here's the pics:

 

[7981GS]

Looking fantastic! How did you get that final drive to sparkle? Nice.

Daniel

 

[Guest]

Hey, good to see more Europeans joining the site ... and good work there!

That 4-2 exhaust looks interesting. How available are they and what do they sell for, if you know?

You guys overseas got the much cooler paint jobs.

FC, I agree, I think the USA market got rather understated paint schemes...

 

[Guest]

Any tips on how to join frame and engine without breaking my back AND keep the coating on the frame undamaged?

"Lay the bike on the side" seems by far the easiest method.

 

[Digitus]

Looking fantastic! How did you get that final drive to sparkle? Nice.

Daniel

Thanks ! I just polished the thing, sanded out the weathering with 240 on a sanding machine, then polished with the sisal wheel, then the buffing wheel.

I'm too lazy to do the 600-800-1000 sanding by hand

 

[Digitus]

Hey, good to see more Europeans joining the site ... and good work there!

That 4-2 exhaust looks interesting. How available are they and what do they sell for, if you know?

FC, I agree, I think the USA market got rather understated paint schemes...

I bought a 2nd hand complete set for 175 euros incl shipping
New set of just mufflers is still here on the local classifieds site for 175 ex shipping. http://link.marktplaats.nl/465438066
Still dont know if they fit, gonna try that today

 

[Digitus]

Exhaust are on the bike and they fit like a glove. They came off a 750, so I didnt know if I could use them :dancing:

 

[Nessism]

Looks great! You are obviously a skilled craftsman. I love the way you used the sling to hold the engine. Great work and thanks for sharing.

 

[Digitus]

I got the wiring back on the bike ! Another big step.
I have done:
-Soldered all original connections back on the loom
-Cleaned all plugs
-Re-wrapped large parts of the harnass with textile wire protection tape
-Cleaned all wires
-Sanded all the ground connectors and measured ground resistance between frame, engine and battery

It was a LOT of work, glad its done.

I decided I'd bring the electrics exactly back to the original state and then check all functions. From there I can do suggested mods that I read about on the forum. If I incorporate them right now, troubleshooting will be a nightmare.

Soooo, I hooked up the battery and checked ... everything works EXCEPT the neutral, oil pressure and gear indicator. .....bummer.
Havent got the time to hunt down that problem right now. I assume GI, neutral and oil are all switched to ground, so I suspect a power failure in the clocks somewhere..to be continued