1981 Suzuki GS650E Project or Money pit?

[jdvorchak]

I have made battery terminals out of copper water pipes. Cut off a 1 or 2 inch piece of small tubing and flatten 1/2 with a hammer or vise. Drill a hole in the flattened part. Using solder paste or small wire brush make inside and outside surfaces clean and bright. Then with a propane torch solder the old battery cable onto the end. You can make any size terminal you want.

 

[wyly]

Found that front calipers, after opening them up, have almost perfect pistons, seals seem spongy, they weren't leaking originally, and all slide boots and dust seals are in good shape. Would anyone recommend putting the originals back in, or is that a taboo thing? It's 50 bucks i would save, but I bought them with my safety in mind.

if you already have the brakes apart rebuild them you're just going to do it sooner or later anyways. And your life is worth more than $50.

 

[SuzukiNoob88]

Thanks for the tips wyly and jdvorchak, i have heard of tinfoil and water, but never thought to use vinegar, and all I use for rust and part removal is PB blaster and Marvel Mystery oil.

Unfortunately am waiting for an 8mm Irwin bolt-grip socket to remove ONE of my exhaust bolts that broke off about half an inch from head.

Also, can't seem to find the proper O-ring for oil pan oil passage, which didn't come with OEM gasket. I used a measure to determine a 3mm thick 20mm OD ring.

I installed a 45 degree fitting on swing arm pivot to aid in future lubing.

Tasks until ride-able and inspect-able:
- oil pan install.
- oil flush and filter change, will add seafoam and then possibly do another oil change in near future
- headlight (sealed beam or conversion to halogen bulb) and install replacement housing
- find exhaust, either stock or new to replace detached muffler on left side and pin hole starting on right side in same area.
- Fix horn circuit, switch seems to work when I check voltage at horn, and horn works when isolated from bike
- mirrors
- ***Rebuild all brakes except front MC to be replaced with new MC and reservoir(disassembled and partially cleaned up to naked aluminum, unintentionally, will be polishing them a little, got sidetracked from original purpose on this one)
- Replace battery with proper sized one exceeding oem (previous owner had undersized battery)
- check throttle, and choke and clutch adjustments.

 

[jdvorchak]

I've had really good luck with Harbor Freight Left hand drill bits and their easy outs. Lots of PB and heat it to dull red prior to extraction.

 

[jdvorchak]

I always say a 15 minute job is only one broken bolt away from a weekend long ordeal.

 

[hillsy]

I'd re-use the caliper seals - they are either going to leak or not leak. They wont suddenly "disappear" and leave you with the lever back at the bars.

 

[jdvorchak]

Actually if the seals are flexible and spongy but fit tight in the groove and the piston is not seriously pitted I've re-used them. If they are going to leak you'll know about it before you ever ride it. Just keep an eye on the brake pad next to the piston and make sure it's dry. Also if it leaks the lever/pedal will slowly go down as you hold high pressure on it for a few seconds.

That being said. since you already have it apart, the prudent thing to do would be to replace the seals

 

[JJ]

When I rebuild a caliper or master cylinder on any vehicle, all of the rubber parts get replaced. Stopping is important!

 

[Guest]

Sorry folks, I guess I am bad at communicating. I definitely didn't buy this to "flip" for a profit after a quick oil change. What i mean when I say "money pit" is the same thing folks mean when they buy a $200 car to commute that wont pass inspection (which this bike doesn't).

Btw, thanks to all of your honest opinions on the matter, because I was afraid to hear some of it, but glad to get straight up answers.

No original plan, because I know that it's rare to find a bike this old (or any bike for that matter) under $1000 ready to ride, was to get it SAFE and Inspected, and then worry about thoroughly running through the mechanical when the fall and winter hits.

I had an 82 Honda CB650 (paid $1300 but was in very good shape, almost no rust) when I got my License 8 years ago, and loved the style of these older Japanese bikes. I really can't see myself riding a crotch rocket, or a laid back cruiser.

I'm definitely not worried about riding more than 50 miles at a time, and maybe an occasional commute if I can get it SAFE and road-worthy.

Wow! You sound like me.

 

[jeffgs]

Look, I was in the same position. I had to get over what the bike was worth to others and focus on what it was worth to me.

Total cash flow I am sure I could have purchased a new bike. New bikes do not have personality. I would ride mine anywhere with the confidence of a new bike, it just has quirks and it's own personality.

That is how it boiled down for me. I may have to sell it now because I had a huge Motocross wreck and I cannot bend my knee, so I have been looking at newer machines with forward controls. I cannot make up my mind because I lose interest in them.

 

[wyly]

Thanks for the tips wyly and jdvorchak, i have heard of tinfoil and water, but never thought to use vinegar, and all I use for rust and part removal is PB blaster and Marvel Mystery oil.

cleaning solution...Pine Sol

Ridiculously inexpensive I used it to clean my carbs, it even pealed the paint off. When I soaked my carbs in the dining room the wife didn't complain about the lavender scent.

 

[wyly]

I'd re-use the caliper seals - they are either going to leak or not leak. They wont suddenly "disappear" and leave you with the lever back at the bars.

that could be true but if it's already apart why repeat the procedure, save time and do it now while it's apart.

 

[wyly]

Sorry folks, I guess I am bad at communicating. I definitely didn't buy this to "flip" for a profit after a quick oil change. What i mean when I say "money pit" is the same thing folks mean when they buy a $200 car to commute that wont pass inspection (which this bike doesn't).

.

I'm in the same position as you are. I inherited a 84 GS1150EF that wasn't running, it'll have cost me $3K by the time it's finished this week, about what it's worth. So I not looking for a profit just a safe fun daily ride/commuter.

My last chore now is brakes, it's been at least 25yrs since the brakes have been looked at. I'll change the fluid and ride it up and down the street to test them, they appear to be good but I'll rebuild the master cylinder and replace the caliper seals. After spending $3K I'm not going to cheap out now on $70-100 worth of parts that could save my life.

 

[SuzukiNoob88]

Update on my rebuild:

-All brakes, are rebuilt and bled (had to buy rear pistons from suzukipartshouse.com, but came with seals for 37 plus 9 bucks shipping.... they nail you on shipping)
-New right front master cylinder due to inability to rebuild old one (couldn't remove piston from housing)
-New front tire (due to dry rot after i filled original with rated pressure)
-Rear swing arm bearings replaced
-New battery (replacing POs harbor freight junk)
-Headlight from 1980 gs450 and headlight retrofit to halogen.
-Front fork cover (rough but original)

Cleaned brakes to bare aluminum, cleaned front forks and steering.

Thinking about 3d printing some side covers at some point, have access to $3k printer that can print up to 8 inches wide.

 

[Charlie G]

Sort of lost track of your thread on the 650e. Glad to see your giving it a go! Keep it up.