1983 Suzuki GS850 Cafe Racer Project

[mikerophone]

I work in my carport unless it's winter, then I work in my shed for a little additional warmth. It's 30 degrees F here right now. Time to fire up the propane heater!

One day I'll build a garage, or move to a house that has one. My work allows me to do certain things as well but I can't leave anything overnight.

 

[Dirty Deeds]

I do the same. However I am not allowed to perform any personal work at work anymore, the new director is a dick

 

[mikerophone]

That stinks! Personally, I don't see the harm as long as you clean up after yourself.

 

[Dirty Deeds]

Alright, got some work done today.

Changed the secondary drive gears, now the yolk will stay in place.

I also assembled the front end and lowered the front 1". I think I will lower it a little more to keep the lines of the tank and seat horizontal. In addition I installed the swing arm and shocks. Yes I still have to paint the rear rim.

I included a pic with the tank and seat on the bike so you can get an even better idea of the look I am going for.

Tomorrow I will install the short block and start assembling the engine, we'll see how far I get. I'll post more pics tomorrow.

Sorry about the quality, they were taken in the dark by incandescent light with a cell.

 

[Weasel]

Looking great DD, nice work.

 

[Dirty Deeds]

Thanks.

Got the engine in today. Still need to do the cams and timing.

 

[Weasel]

I was thinking ahead to drag bars or clip ons, I really like the way yours turned out.

 

[Dirty Deeds]

Hello again.

You won't see this in the pics, but I changed the drive-shaft. I also started to set up the hand controls, foot controls, rear brakes, and painted the rear wheel.

Enjoy!

 

[GS1150Pilot]

That L is looking great!

 

[Dirty Deeds]

Thanks.

I was worried for awhile as this is my first build attempt.

 

[Dirty Deeds]

I got some more work done over the holidays.

I installed the cams, checked the valve clearance, and tightened everything from the rear wheel to the neck. I also filled the engine, secondary drive, and final drive with fresh oil. After that I installed the carbs and air filters, and then rechecked everything a second time.

Next I will be finishing off the brakes, hand controls, and all cables. When this is done then i will be into the home stretch with the wiring and fuel tank. The fuel tank has some sleight rust that I will have to deal with and the fuel level sender doesn't work at all, but I have an idea that may work as a modified replacement as that part has been discontinued for years.

Then its prep and paint for the tank and exhaust.

Then it'll be cross the old fingers and hope it starts after 5+ years and all my hard work.

Anyhow here are some pictures.

 

[revilo]

Looks great. Is it just me or do the L's have a smaller rear wheel?

 

[Who Dat?]

The Ls have a 16" wheel, the Gs have a 17" wheel.

Except for the '80 850L, which has a 17" wheel.

 

[Dirty Deeds]

I have read a few threads and websites on carb rejetting, but to tell you the truth, I am a little unsure about that.

Does anyone have any idea where to start, going from a stock set up like this......

To using pods and a slip on muffler like this one?

http://www.ebay.com/itm/171434479222

Some input would greatly be appreciated.

Thanks

 

[Weasel]

Did you come across this post yet in reference to pods & rejetting?

http://www.thegsresources.com/_foru...-Pods-Pipes-Panic!-(Help!-Your-Bike-has-Pods)

 

[Dirty Deeds]

No I didn't. Thanks Weasel.

I haven't had any time to get anything else done on the bike since my last post.

I'll keep you posted as usual.

Thanks again.

 

[ShadowFocus603]

Hate to say it but the first place to start is getting rid of those narrow cone filters and getting a proper set of filters from APE or K&N. Those filters more than likely have the same issue I saw with another similar set I got where the inlet is necked down where the rubber joins to the metal base of the filter. If the rubbers diameter is less than the outer diameter of the carb then you will see restriction. Then order Dynojet kit 3306. It's not just jetting you need. You also need the needles included in that kit. I have the same motor you do and that jet kit along with the APE filters is what I am running. Install the largest jets in the kit and set the mixture to the manual in the kit. I haven't had to touch mine since install. I think I am running a 17.5 idle jet.

 

[ShadowFocus603]

BTW the bike looks great. I love where you have gone with it.

 

[DohcBikes]

Hate to say it but the first place to start is getting rid of those narrow cone filters and getting a proper set of filters from APE or K&N. Those filters more than likely have the same issue I saw with another similar set I got where the inlet is necked down where the rubber joins to the metal base of the filter. If the rubbers diameter is less than the outer diameter of the carb then you will see restriction.

Not only will it cause overall restriction, often times the inner parts cover the air bleeds. This will make the bike virtually untuneable.

Rear tire is going to slam into the seat pan over hard bumps. One of the most common mistakes made by the new wave of builders.

You might find that clipons with no rearsets is very uncomfortable on long rides.

It does look good, but form follows function. Cheers and good luck with the project

 

[Sebastian24]

Looking very good! I'm in the process of doing the same thing ( had to do a lot of maintenance stuff and collect parts first).
What are you looking to do as far as rear sets?
And are you deleting the turn signals? If so, a diy would be great ( the harness on my bike is so hacked up, I can't make any sense of it, even looking at the diagram for it)