1980 Suzuki GS850G first every rebuild! (need help haha)

[andrewmac805]

Hello all knowing GS Resources!

Here's my first GS and my first post!

I got myself a little project over the summer to keep me busy while I wasn't able to work. I've never worked on a motorcylce before, however I wanted to learn about engines and mechanics etc as I thought it would be useful in my life as a commercial diver (if it's broke, you fix it! So better know how to fix stuff!). And at the end of it I wanted a bike to ride up the West Coast!

I picked up this sorry looking GS850 from craigslist. The previous owner got it as a free bike thrown in with the purchase of another GS, a parts bike! It had all the vetter jazz on it, however the previous owner had already sold it all before I got it:

Here's how I got her:

I was very dedicated to getting her fixed up when I first got her and got some good deals courtesy of Chef1366 and was introduced to the great forum.

From then I have been trying to read the relevant topics and trying to understand stuff! Thank you so much BassCliff for your awesome website!! It has been invaluable!

So far I have:

Replaced the battery
Installed a headlight bucket and ears
Installed and and bled a new front brake system
Cleaned the rusted gas tank with the VINEGAR method! Worked a treat for me! Copied this guy mainly http://www.mopedarmy.com/wiki/Removing_rust_from_a_gas_tank#Vinegar
Installed new intake o-rings and allen screw set
Replaced the spark plugs
New airbox boots
New Uni air filter and weather stripped the airbox
Tried to rebuild the carbs but the rail screws we in sooooo tight I couldn't get them out! Not even heating them and spraying PB blaster could free them!
So I cleaned them with the pinesol method and anything that I could fit in the ultrasonic cleaner and the carb dip! Replaced all the o-rings I could get too.
Got a nice tail light lens!
Tried to get a petcock but was for the later model GS850's so didn't fit
The only one's I can find are the ones that don't come with a lever?!?! What good is that? Where do you get a lever to turn the petcock to prime and reserve? If anyone know's I'd appreciate the info http://www.siriusconinc.com/pro-detail.php?pid=&product_id=1004 *TAP LEVER NOT INCLUDED* eh?!

So that's about where I am now! When I reinstalled the carbs, the bike was only running on 3 cylinders think number 2 wasn't firing (header was cold). So I was dissapointed and had bought another bike project so was working on that as well (Honda CB750F) and my father-in-law went and bought 3, yes I said 3, Honda CB900C's for me to rebuild for him since I was doing my own! And yes none of his run either! So it was safe to say I was over my head in bikes!

Then I was finally able to work and have been working my ass off since! 120-150hrs every 2 weeks! So haven't had much free time!

I have now had a second wind! I tried to start the GS850 a few weeks back for the first time in months and couldn't get it to go, so sprayed a little too much starter fluid in the air intake and she ROARED into life again!! And this time she was running on all 4 cylinders, blew that crap right out her carbs I guess! Yey ether!

So took her for a spin finally!

However, at idle if I move the handlebars hard left or right she idles way up, to >4000rpm so I guess the throttle cable is too tight or something so have to buy a new one?

And my biggest problem now is that she won't hold a charge
After a short 30min ride around the neighbourhood once I turn her off she has no juice to crank herself back to life.
So I guessed it was a stator or R/R problem since there is a lot of talk about it on the forums. I went and bought a multimeter today and I'm a little lost! I know nothing about electronics. I followed the wires from the stator to the R/R and found one wire wasn't connected, so thought that may have fixed it, so plugged them back together and crossed my fingers! But to no avail! She still didn't hold her charge. I did notice another wire that wasn't connect and I can't find where to plug it in! It travels with the other wires towards the starter cover it just reaches inside the cover but isn't connected to anything. It has a small plastic clip in style connector but I can't find anything to clip it into :-k any thoughts?

I tested the battery after I took it off the charger. It read ~12.3V. Started it up and at idle it read ~12V and when I revved it up to 4000rpm and higher it went back to ~12.3V but didn't climb any higher. I know all these values are lower than the anticipated values you should get, but it doesn't seem like the characteristics of a stator or R/R problem since the Voltage didn't drop. Am I correct or just plain confused?!

The wiring on the bike is all over the place cause of the horribly spliced in vetter wiring and my hack job to remove it! So could a short or something be draining my battery?!

Any help would be greatly appreciated! Sorry for the life story about the bike and my rebuild haha!

Thanks for reading it all!

Andrew

 

[Nessism]

Hi Andrew,

I'm in Torrance and will be glad to help you out. Fixing the charging system is easy. As for the petcock, you need...

Part# 44300-45011 Desc COCK ASSY, FUEL

PM me if you need any specific help or advise.

 

[andrewmac805]

Hey Ed,

Thanks for reading my post and replying! Any help I can get is appreciated! I have no idea where to start with the electricals at all! When are you free to lay your knowledge on me?!

I looked at some of your pics, damn your GS850G is CLEAN!!!! How did you get it so shiney everywhere!?

And you are brazing bicycle frames? That's pretty damn cool. Did you make yourself a custom bicycle? When I first came to america I volunteered at a community bike shop in Santa Barbara and built a couple bikes out of scraps up there! So I graduated building bicycles to try motorcycles haha! A little tougher!

 

[7981GS]

With Ed near by and offering to help, you are set!
She'll be purring like a kitten in no time.

Daniel

 

[andrewmac805]

Sweeeeeeeeeeeeet!

Thanks Ed and Daniel! When you guys free?

 

[Nessism]

Andrew,

I'm free most evenings and often on weekends. What's first on the list? Charging system?

Ed
310-809-6038

 

[andrewmac805]

Yeah if I could get the charging system fixed I think I can handle the rest!

Just little bits here and there I need to get done. I ordered the morgan carbtune and tool, so will sync the carbs when that comes.

Before that I should really check the valve clearances, I have the little valve shim tool but a bit nervous to get stuck into that.

Then it's just the throttle cable replacement and cosmetics.

O and need to easy out the rear brake bleed nipples, a snapped them off

Damnit! The more I think about it the more stuff I have to do! The end is always so near yet so far!

Are you free anytime tomorrow? I'm going to be home all day working on the bike.

 

[Nessism]

Are you free anytime tomorrow? I'm going to be home all day working on the bike.

I should be home by mid afternoon. Could help you out then. Charge the battery and ride it over? I have a spare R/R if we determine your bike needs one.

 

[BassCliff]

Greetings and Salutations!!

Greetings and Salutations!!

Hi Mr. andrewmac805,

So you know Bill? Well, we won't hold that against you.

Check the routing on the throttle cable and make sure there is no binding or kinks. Download the manual and look at the routing charts.

You'll find lots of GS850G lovin' on my little website, how to fix the charging system, how to adjust the valves, etc. You've done great work. Keep it up.

Let me dump a TON if information on you and share some GS lovin'.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. Now let me roll out the welcome mat for you...

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

 

[andrewmac805]

PM sent to you Ed.

 

[salty_monk]

You're in good hands! I'm local too but not much time to play these days!

 

[Nessism]

You're in good hands! I'm local too but not much time to play these days!

What you doing tomorrow afternoon Dan? :-k

 

[BassCliff]

Hey Ed,

Are you guys going to have a wrenching party?


Thank you for your indulgence,

BassCliff

 

[andrewmac805]

Thank you very much for your warm welcome BassCliff!

Haha, yeah I met Bill up in Santa Barbara to pick up some parts before summer, man I haven't worked on my bike in a long time! Very nice and helpful! Glad I went up to see him.

I tried to see if the cable was binding on anything, it had a cable tie thing on it and I took that off to see if it helped but it didn't. Think it's just old and worn out. I'll check out the manual to double check if it is routed the right way tho!

As for the valve adjustment, I'm just worried I'm gonna need to buy and replace a whole bunch of shims!

She has almost 75K miles on her, so I'm sure she's a little worn out!

Thanks again,

Andrew

 

[andrewmac805]

O wow Salty_Monk you really are local to me! I'm in North Redondo. Do you happen to be from Scotland too? I think Bill may have mentioned you when I met him. I'm from the ever beautiful Dumfries!

 

[Nessism]

I've got a good sized bag of shims, and a couple of shim tools. If you can get the valve cover loose before hand we adjust the valves easily enough. The hardest part of the job is cleaning off the old gasket if it's stuck.

 

[andrewmac805]

Thanks Ed! I'll try get on it first thing 2moro morning!

Do we need the bike running to test the charging circuit tho?

Guess I'll go buy some gasket material from an autoparts store so that I can use the gasket fabrication tutorial on the BikeCliff website! I'll try have the gasket ready so it'll be quick to reinstall after the valve adjustment.

 

[andrewmac805]

A big thank you to Ed for helping me last weekend!

We got my front tire changed out so it's actually safe to ride!

And we got the valve adjustment started. A few of the clearances were a little tight but luckily Ed had some spares. Had to order a couple 2.30 shims and they just arrived yesterday, so got them installed today, so my clearances should be good for a while now!

I used the tutorial to make my own gasket. Prob be the last time I do that haha! Took me a good few hours trying to trace out the shape and cut it! I'll just spend the extra money and buy a pre-made one haha!

Tomorrow I will try tackle the charging circuit! Fingers crossed it's the R/R and it'll just be an easy swap out! I think I just jinxed myself!

Just get the bike running and check the AC coming out of the stator yeah? If it reads around 65V I should be good on the stator and I'll have to switch out the r/r.

My morgan carbtool also arrived this week, so now my valves are adjusted I can sync my carbs!

 

[andrewmac805]

OK! I tested the stator. It just stays around 12-13V when I check across all the stator wires at 4000 RPM

Poop need a new stator then. Does anyone know about these stators? http://www.ebay.com/itm/Stator-Suzuki-GS850-GS850G-GS850GL-GS850GD-1980-1983-/330546581212?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item4cf61c8edc#ht_5245wt_952
I am tempted to buy it cause it is $20 cheaper than the other ones and it comes with the little rubber plug!

Rode the bike round the block anyway since it was running. Ed fixed the handle bar turning idle up problem! I had no play in my throttle! So any tension caused it to idle up! The new front tire is great! Can turn into the corners much better! However she bogs down real bad when you try get off the line. Guess I need to sync the carbs soon.

 

[Nessism]

Hi Andrew,

You checked the stator using the AC setting on your meter right? Assuming yes, stator time for sure.

Not sure about that stator. Makes me nervous. I recommend a Rick's, only they are about $130 so easy for me to say.