1982 GS650G Cafe build

[LowellGS]

See I know those weren't valves I know what they do and their purpose. Just bare with me on the wording. I'm really really bad with words. And my manual doesn't helpe me out at all. It will call the same thing two different names. I'm just not good with words on top of it.

The monshocking is like a year or two away if I ever do it. Its not like a two month away type of deal. I want this project to atleast take a year soo don't think it will be done this season.

But anyone know how to get the outside pistons up so I can clean them? A wire brush aint about to be able to reach them where they are

Also my manual says to use cleaner and doesn't specify any? Any ideas on one to clean all the carbon bull**** off.

 

[LowellGS]

Going to be ordering a gasket kit off Oldbikebarn by Athena..for 103

They have a real nice 4-1 for my bike to but i don't have 450 laying around right now

To Do list:
Frame work:
Take off the swing arm (need bigger allen wrench)
Mock up wiring to figure out what i need to fab up (started today) scared myself a little bit lol
Remove old tabs (buy a grinder looking at the dewalt dw402)
Get shocks
Get/make seat/tail
Make seat/tail supports/ignition support
Batt Box
Tail lights/head light/Blinkers
Take all apart
Grind welds
Paint


Engine
Remove old gaskets 75% done
Get new gaskets
Assemble
Clean really really well (boil)
Self Etching Primer
Figure out paint scheme.



Well i finished taking the brakes off and wheels.. Need to get new wheels and brake pads as well.
The thing with the welding I have to depend on a buddy of mine who is a flake. I know he can do good work, but i may be waiting 6 months for him to just start it.

 

[TheCafeKid]

Are you for real dude?? Im starting to think that this whole thread is someone playing some tom foolery on us..

Have you READ ANYTHING on this site? At all?

First there was a whole diatribe on Athena and Vesrah Gasket kits and how much they are a waste of precious money and worthless for doing anything with other than maybe making paper dolls out of..

Secondly, there are also many posts about OldBikeBarn and what a bunch of rip off artists they are. DO NOT BUY ANYTHING FROM THEM..You wont get it, and you probably wont get your money back.

Thirdly, as many people have stated on this board, if you pull the head, you need to pull the jugs(cylinder bores) as well, because youve very likely disturbed the base gasket (yes there is a gasket between the cylinders and the cases) that will leak if you dont replace it....


Its starting to look like there is going to be a mangled 650G for sale in the near future..

 

[Suzuki_Don]

And DON'T dare touch the piston tops with a wire brush. You'll mess up the pistons. They're only alloy you know, not cast iron.

 

[BassCliff]

Hi Mr. LowellGS,

I admire your enthusiasm. To turn the motor, most of the time you can just put a wrench on the bolt under the ignition cover. Normally you will turn the motor in the forward direction only (clockwise). This is standard procedure when performing a valve clearance check.

Thank you for your indulgence,

BassCliff

 

[LowellGS]

And DON'T dare touch the piston tops with a wire brush. You'll mess up the pistons. They're only alloy you know, not cast iron.

Really? My manual told me to use one???

Also Ive order from Old bike barn before once and got everything? But Ill definitely take your word for it

Yea i pulled the whole top end.. and if you read my posts you would see that i'm taking off the gaskets. Guess i figured a gasket was a gasket but i guess i was wrong, I was just pretty pumped when i actually found a gasket for my bike, because i haven't been able to find one

And if it was mangled who cares it was free and not running.. At least i had fun...Learning a lot and that's the entire point of this bike.
If i wanted a nice bike i wouldn't get one that was sitting for 9 yrs

 

[TitanNeil]

For the carb boot screws, go buy an impact screwdriver (spring-loaded, designed to be hit with a mallet). It should cost you $7 to $15 for a set, and you will love it forever. Bike repair or restoration is impossible without it.

 

[504-Ranger]

x2 on the impact driver, got one for 5 bucks at harbor freight and it made taking the left side sprocket cover a breeze!!!!! plus its cheaper than a set of bolts to replaced the stripped ones so theres no reason to not buy it

 

[LowellGS]

Good idea.m but I already tried with one of those grabits so the screws al already hollowed out pretty much.they were so siezed the grabit broke off. I have no idea what to do now. But ill defitely pick one of those up

 

[Guest]

Good idea.m but I already tried with one of those grabits so the screws al already hollowed out pretty much.they were so siezed the grabit broke off. I have no idea what to do now. But ill defitely pick one of those up

By grabit you mean an easy out?

 

[LowellGS]

No I mean grabit. Its a bit for a drill hence the grabit

 

[Turtleface]

By grabit you mean an easy out?

Yes, he does. Grabit is a brand name of screw extractor. So is Easy Out.

 

[LowellGS]

ahh ok lol

I'm going to end up taking it to someone to have them removed?

Also i hate gaskets by the way.. I'm going to end up using an athena kit.. ive seen posts of people bashing them and posts where people say they have had them on their bikes for years without a problem.

I found the kit for a good price like $70. Gonna finish off the engine before i move onto the frame work..

I'm trying to figure out how to paint the engine.. can't find many pictures on here..
I need to like tape off every bolt hole?

 

[LowellGS]

So its been a while obv..

Some updates..
Finally finished taking all the gaskets off

Just picked up some airplane stripper for the frame and tank..

I just ordered a gasket kit for the engine. About to order a bolt kit.

Questions to you is.
The jugs are off the bike. Top end in pieces.
Should i put it all back together then degrease/clean it or do it now while its in pieces?

Also what should i use? I have heard of kerosene, engine bright and simple green mixes??

What do you guys think

 

[waterman]

I would clean and degrease all of the pieces before you reassemble. If you are still planning on painting engine, paint the individual components and then reassemble.

As for cleaning, I have used Purple Power degreaser. I will warn you to follow directions and use gloves, the stuff did a number on bare skin. Kerosene will work as will engine bright. I just rinse well with water after cleaning and blow dry with compressed air.

 

[Skateguy50]

goodluck on this, getting my cams on tonight from my second top end rebuild.

I like you heard both stories on the Athena's and the price was right so I went for it. I will say clean it as good as you can, take your time lining it all up on reinstall and make sure it has all the orings, if not get some... the kit only came with 2 orings for the head gasket so I used 2... well it needed 4 and leaked. The base just got cooked and lost a chunk in the middle and cracked all over, was about 6k till I took it off but leaks started about 3-4k miles in.

Athena Head gasket, did ok but should have bought extra orings:

Athena base (ironically this one sucked the most and was actually reasonable as OEM $20 vs $120 for head gasket)

That piece in the middle was not stuck on the cylinders, it was long gone and the source of most of my oil leaks.