1980 GS850 Rebuild

[Guest]

I've spent a little more time tying up wiring loose ends, but it's still a little flakey. I'm thinking when I do a complete tear down, I might unwrap the harness and give everything a good inspection and clean up. As it is, it's the kind of thing that could leave me on the side or the road (or on fire).

I also installed the new manifolds. I didn't run it long enough to thoroughly warm up, but there's a noticeable improvement in the way it runs. Score!

I'm still at least two weeks from able to ride, so I'll go ahead and adjust the valves and then sync and adjust the carbs. By the time I'm back on my feet, the bike should be as well.

I didn't mention before, but this isn't my first GS. Here's a shot of resto I did a couple of years ago. 1983 GS1100es.

 

[Steve]

Nice paint on the ES. :encouragement:

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[Guest]

Nice paint on the ES. :encouragement:

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Thank you! I did that myself. That was a fun bike. You really need to see the "before" pictures to appreciate the transformation.

 

[Steve]

The ES was a one-year-wonder, pretty much like the '78 1000E, which was known as the "Skunk". The ESes that came here were all blue on white. Not sure if there were other color schemes in other countries. It is somewhat amusing to see the efforts that some will go through to duplicate the stock blue and white EXACTLY, and here you come and show us what appears to be a couple different shades of gray. Done very nicely in the stock pattern, it REALLY looks good. :encouragement:

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[Guest]

The ES was a one-year-wonder, pretty much like the '78 1000E, which was known as the "Skunk". The ESes that came here were all blue on white. Not sure if there were other color schemes in other countries. It is somewhat amusing to see the efforts that some will go through to duplicate the stock blue and white EXACTLY, and here you come and show us what appears to be a couple different shades of gray. Done very nicely in the stock pattern, it REALLY looks good. :encouragement:

I bought the ES in running, but pretty rough shape. It was blue and white like you mentioned, but showed its age. The seat had been recovered in blue crushed velvet, and the unobtanium gauges had been smashed. In my opinion, grey with a splash of color always looks good, so that's what I did. It was a project and I eventually had to sell it (wife say's I can only keep one), but it was fun while it lasted.

Back to the GS. I checked the valves late last week. The first one I checked was on the loose end of in range (0.07mm), so I felt pretty good. But, all the rest were super tight (now I'm more concerned about the one that was in range). I was able to get two more in range by swapping shims around, but I had to order new shims for the rest. They should be here around mid-week. I also found that my petcock has a slow drip, so I'll be messing with that in the meantime. I may end up getting a new one, but I'll try to repair first. It's slowly coming together.

Here's a shot of another project, also from a couple of years ago. This was supposed to be for my son, but he lost interest. What's wrong with kids these days?! I'd have been thrilled to death if my dad had done something like this with me! Anyway, I'm thinking about something similar for the GS, but I think I can get the proportions a little better this time. I feel like the tail is too short on the KZ. Learning all the time!

 

[Guest]

...and another from the side.

 

[Guest]

Valves adjusted, carbs synced and adjusted, tank and seat are installed. The only problem is that the doctor said I should stay off bikes for another month. But the weather was nice, so screw it! I took it for a spin around the neighborhood, and it ran great! A few things still need adjustment, the biggest concern being the clutch. It was a little tough to get into neutral after it had warmed up. Otherwise, it was a really nice and smooth ride.

A big part of the reason for taking it for a ride was to locate the oil leaks the PO had mentioned. I was afraid I would be looking at a base gasket leak, but everything looks tight and dry. The only leak (and it's a good one) is from the tach cable connection. The PO had removed the cable and plugged the socket with what looks like hard silicon. It's not sealing, and since it's on the front of the engine the oil makes its way everywhere. This should be cheap and easy to fix.

Another milestone checked off, and time to spend more money. Next step will be to get it street legal and put some real miles on it.

She's still not much to look at, but here's a shot I took after I got back from the shakedown cruise.

 

[Guest]

....and another one of my old projects. 1982 Virago 920.

 

[Guest]

Over the last couple of months, I've been able to put 50-75 miles on it, and it looks like I've still got an oil leak (leaks?). Maybe base gasket, but I was reading another post about the cam chain tensioner being a common problem. Once the weather improves, I'll clean the engine so I can pinpoint it.

Also, I'm probably looking at a new clutch. In addition to the problem getting it into neutral, I can make it slip in top gear at highway speeds. So that's on my list now as well.

My biggest accomplishments are finishing up the wiring repairs, replacement of the gauge cluster (old one was toast), and I've built a flat track style seat using the stock pan. There's still a long way to go, but I'll keep chipping away.

 

[oldGSfan]

I used just a little of the engine dye and UV light on my GS1100E and it really helped, I thought I had a head or base gasket leak and it turned out to be two leaks from the half-moon shaped cam rubbers. Those leaks have mysteriously stopped, maybe riding swelled them, and the return feed to the turbo was spitting oil all over which was just an overzealous tightening that must have distorted the O-ring. Now it's not leaking, fingers crossed.

Over the last couple of months, I've been able to put 50-75 miles on it, and it looks like I've still got an oil leak (leaks?). Maybe base gasket, but I was reading another post about the cam chain tensioner being a common problem. Once the weather improves, I'll clean the engine so I can pinpoint it.

Also, I'm probably looking at a new clutch. In addition to the problem getting it into neutral, I can make it slip in top gear at highway speeds. So that's on my list now as well.

My biggest accomplishments are finishing up the wiring repairs, replacement of the gauge cluster (old one was toast), and I've built a flat track style seat using the stock pan. There's still a long way to go, but I'll keep chipping away.

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[Guest]

I've had to split time between my GS and my XR lately due to cratered splines on my XR's countershaft. The Honda's engine is in pieces, and while I'm waiting on parts I was able to get back to the GS.

So I cleaned the engine up, and last night I used the foot powder trick to try and find my oil leak(s). The only thing that turned up was a rock hard o-ring on the oil pressure switch. I swapped that out and everything seems to stay dry, at least while idling in my garage. It's supposed to get into the 50's today, so I'll take it for a ride after work and see what happens. Fingers crossed.

PS: Pretty sure I still need a clutch. I'll make the call on that after today's ride as well.

 

[Guest]

I went for a ride yesterday and can confirm that I still have oil leaks. My cam chain tensioner is definitely leaking, so new o-rings and seal are on order. It also looks like it's leaking from the left side either at the base gasket or at the top of the left side cover. I replaced the side cover gasket previously, so I don't think that's it. It could possibly be traveling from the tensioner, so I'll fix that first and see what happens.

My clutch acted better, and I wasn't able to make it slip. But it's still grabby when in gear (feels like it doesn't completely disengage), so I'll have to look into that. I'll probably take it apart and inspect before I buy new disks.

 

[Guest]

Resealed my tensioner, so it doesn't leak, but I still have a leak on the left side. It still appears to be coming from the base gasket, so I've ordered base and head gaskets and o-rings. Base gasket is back ordered, so while I'm waiting I tore everything apart. I striped the rattle can off (acetone, yummy), sanded and painted the frame. Did the same with the wheels, and I should have those painted and a new front tire on tonight (rear tire is nearly new, so won't be replacing that one). New fork oil and seals after that.

 

[Guest]

My gaskets and o-rings all finally arrived, so I was able to get the engine back together and into the frame. I've been able to make some good progress getting the thing reassemble. I should have it running next weekend, but I'll have to get the WaveRunners out of the garage before I can paint the tins. They've got issues too, so it may be a few weeks. Some photos of progress so far.

 

[Guest]

And another since I haven't figured out how to attach more than one picture per post.

 

[Grimly]

And another since I haven't figured out how to attach more than one picture per post.

View attachment 62668

I use this service...
https://imgbb.com/
Upload, get the 'full BB code' and paste it into the 'upload image from url' box. Don't forget to untick the 'save file locally' checkbox, as it never works for image files over a very meagre size.

 

[motorush]

How did you attach the rear fender/seat to the frame. Currently in the process.... Nice bike.



And another since I haven't figured out how to attach more than one picture per post.

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[Guest]

The fender and seat are built directly onto the factory seat pan. I formed the fender using flower arrangement foam I got at Walmart, and then fiberglassed over it. So, it still hinges and locks down using the key just like the original seat.

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Update on progress: My plan (at the moment at least) is to paint the bike red with black stripes outlined with silver pinstripes. Something similar to the picture below. Last weekend I finished the body work and sprayed silver for my pinstripe color. The silver turned out so good I was initially tempted to stop there, but it's a little too plain for my taste. I should be able to finish up the paint work this weekend, so hopefully I'll have some more photos to share next week. Fingers crossed.

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[nvr2old]

Really nice job on the seat pan and tail section. I'll look forward to your paint scheme for it. The C clamps hanging by the tank kinda freak me out a bit..

 

[Guest]

The C clamps hanging by the tank kinda freak me out a bit..

That does look a little dangerous.