'81 GS850G Restoration

[93Bandit]

Hello folks. I've finally decided to do something with the '81 GS I bought a few months back. I got it for a song, and originally planned on using parts from it to get my 83 running, then eventually do a restoration of the '81. Well after digging into the bike a bit, I discovered that the overall cosmetic and electrical condition is pretty rough. It shows 44,000 miles on the odometer and I believe many of those were hard ones. That being said, I don't know the mechanical condition yet as it was non-running when I bought it. I pulled the starter and a few other parts from it to get my '83 running so I never had the chance to see if it would run. All that to say plans of restoring it to its original glory are gone. It would cost too much and quite frankly I don't want to do that.

Which is what brings me to this build thread. As I'm sure you've figured out by now, I plan on building a cafe racer styled bike from my '81. Below is a bike I found online which captures what I want to achieve for the most part (Credit to the builder, Mr. Swallow Customs). I like the look of this bike and want to build something very similar to it. I plan on a slightly different color scheme.



Anyways, here's a list of things I need to do, not necessarily in order. It is not an exhaustive list at all, but it's a start.
- Complete tear down, to frame
- Deep clean all parts (Frame, engine, tank etc...)
- Paint engine
- Powder coat OR paint frame & swing arm (maybe some other small parts)
- Paint tank
- Paint wheels
- Rebuild carbs
- Rebuild starter
- Make sure it runs
- New exhaust (undecided 4-2, 4-1, open header)
- Rebuild brakes (MC, calipers)
- New brake lines
- Remove necessary wiring
- Rewire basics
- Mount headlight/brake light/indicators
- New handle bars
- New seat
- ????

I don't have a timeline for this build because I want to take my time. I doubt this will be finished in a years time, but then again maybe it will? I'm sure I will need assistance along the way so I will be calling on you experts to help me out!

I will be sure to document as much of my progress as possible. Pictures of the bike and what I completed today to follow! Stay tuned...

 

[93Bandit]

So here are a few pictures of the bike when I bought it and the condition it was in.

View attachment 57475

 

[93Bandit]

Once I got it home...

 

[93Bandit]

I started stripping the bike down today. I got the front fairing, saddle bags and trunk removed, along with all the brackets. Also started removing some the of hacked wiring from the fairing install... Whoever did that needs to be castrated. They did a terrible job of wiring... Anyways, I need to dig into the wiring harness to find out what I need to keep to reference when I build my new harness, and what I can remove. The next few garage sessions will likely be more disassembly. Here is how she sits in my garage as of this evening. Very dirty and in need of some TLC for sure!



Note: For some reason I can only upload one picture per post. Does this have something to do with my post count?

Also, if anyone is interested in some parts, I'd probably be willing to let some go for a deal. The fairing, trunk and saddle bags are rough, but would probably clean up alright. They definitely would not look good on a show bike, but they're decent from afar and still functional. Let me know if anyone is interested. I can send pictures upon request.

 

[Steve]

Note: For some reason I can only upload one picture per post. Does this have something to do with my post count?

Nope.

Even with my post count, the limit of attached pictures is exactly ONE.

However, if you host them somewhere, you can copy and paste the links of up to TEN pictures per post. :encouragement:

Many of us used to use Photobucket, until they appeared to change the "b" in the middle to an "f".

Some use imgur or other similar places, have not bothered to keep track. :-\\\

.

 

[Burque73]

Lookin' good!

Unbelievable transformation. Very nice work, man!

 

[Steve]

Uh, ... Roger, ... that is his DREAM picture, what he wants his to look like. :-k

Below is a bike I found online which captures what I want to achieve for the most part (Credit to the builder, Mr. Swallow Customs). I like the look of this bike and want to build something very similar to it. I plan on a slightly different color scheme.

.

 

[93Bandit]

Nope.

Even with my post count, the limit of attached pictures is exactly ONE.

However, if you host them somewhere, you can copy and paste the links of up to TEN pictures per post. :encouragement:

Many of us used to use Photobucket, until they appeared to change the "b" in the middle to an "f".

Some use imgur or other similar places, have not bothered to keep track. :-\\\

.

Interesting... I tried using my photobucket but I got the same message, limit of one per post... I'll have to try imgur.

Lookin' good!

Unbelievable transformation. Very nice work, man!

Well I am honored that you thought that is my bike, before and after, but the pictured cafe bike is my inspiration! I cannot take credit for that build. It was built by Mr. Swallow Customs as mentioned in my original post. I hope mine turns out as clean as his though!

 

[Burque73]

Uh, ... Roger, ... that is his DREAM picture, what he wants his to look like. :-k



.

Ha, my bad. That's embarrassing as I obviously didn't read much, just looked at the pics.

 

[93Bandit]

Ha, my bad. That's embarrassing as I obviously didn't read much, just looked at the pics.

It's OK, I can be quite winded at times... :tranquillity: lol

 

[LAB3]

That's a good looking build for sure, I've always liked the look of a bike that appears to be missing a few parts in order to run. Give me a kicker and magneto any day! No, I don't WANT to kick it all that bad, it's the look I'm after.

 

[93Bandit]

That's a good looking build for sure, I've always liked the look of a bike that appears to be missing a few parts in order to run. Give me a kicker and magneto any day! No, I don't WANT to kick it all that bad, it's the look I'm after.

I'm keeping it electric start. It's an 81 so it doesn't have kick start anyways. I don't know if it could even be converted???

So help me out gentlemen. The handlebar controls plastic housings are badly dry rotted and the switches don't feel very good so I'm trying to figure out what to do. I've been looking online for either parts to rebuild them (if you even can?) or aftermarket complete assembly options. Has anyone here had to replace the control assemblies? Or had success reconditioning them? Any recommendations are appreciated. I will post some pictures later to give you guys an idea of the condition.

Thanks!

 

[Grimly]

Have a serious look at later model GS500 switchgear, as much of it is far newer and has a long time to go before it wears out.
Plus, it's still Suzuki, fwiw. I'm using Yamaha LH switch, Yamaha brake master cylinder and lever, GS500 throttle tube on the bars, and when the RH switch pegs out I'll probably replace it with a GS500 assembly. Of course, you couldn't be so lucky as it would be a straight plug-in affair, so be prepared to adapt and convert as needed.
The other GS and the XS have a Honda Deauville master cylinder/lever which is a major improvement on both bikes. The XS also has a Deauville clutch perch and lever, again an improvement.
I'm not fussy about originality, as you can see. I pick and choose parts which are easily fitted and improve the feel, also got several years wear left in them.

 

[93Bandit]

Have a serious look at later model GS500 switchgear, as much of it is far newer and has a long time to go before it wears out.
Plus, it's still Suzuki, fwiw. I'm using Yamaha LH switch, Yamaha brake master cylinder and lever, GS500 throttle tube on the bars, and when the RH switch pegs out I'll probably replace it with a GS500 assembly. Of course, you couldn't be so lucky as it would be a straight plug-in affair, so be prepared to adapt and convert as needed.
The other GS and the XS have a Honda Deauville master cylinder/lever which is a major improvement on both bikes. The XS also has a Deauville clutch perch and lever, again an improvement.
I'm not fussy about originality, as you can see. I pick and choose parts which are easily fitted and improve the feel, also got several years wear left in them.

Thanks for the tips! As far as plug-n-play, I understand not all switches will be the same, however wouldn't it be as simple as just splicing the correct wires for the "new" switches??? I can do that, wiring is no big deal.

Also, I'm picky about originality when it's appropriate. I'd like to keep my 83 as original as possible. However on a cafe racer, its being modified anyways so I want it to function and look right. Doesn't need to be all original parts.

 

[Guest]

Thanks for the tips! As far as plug-n-play, I understand not all switches will be the same, however wouldn't it be as simple as just splicing the correct wires for the "new" switches??? I can do that, wiring is no big deal.

Also, I'm picky about originality when it's appropriate. I'd like to keep my 83 as original as possible. However on a cafe racer, its being modified anyways so I want it to function and look right. Doesn't need to be all original parts.

Try Dime City Cycles. https://www.dimecitycycles.com/moto...and-controls/motorcycle-control-switches.html

 

[Grimly]

As far as the switchgear goes, the one thing I stick to is the layout of the individual switches, because it can make a difference to safety if you have to fumble and remember that THAT'S NOT WHERE IT IS ON THIS BIKE.
From the late 70s onwards the Japanese makers seem to have pretty much standardised (I could be wrong on this) on a fairly universal layout of switchgear, especially of the important ones, like light dimming and horn, etc.
Relatedly, one totally bone-headed design is to be found on the European-market '78 and '79 Suzuki LH switchgear where the main lighting On/Off slider is inboard of the Main/Dip slider and more than once, on a badly-lit backroad, with oncoming traffic in the rain, I inadvertently switched off the lights entirely because the end of my gloved thumb had turned the lights off instead of dipping them. That particular design shortcoming might not apply to US-market bikes, because of the requirement for the headlight to come on with the engine, of course, and the master light switch might be missing from that location.
Not good.

 

[93Bandit]

Hey guys. I've had a lot going on so I haven't been able to work on my 81 Cafe build for a while. This evening I had some free time so decided to open up the old starter from my 83 850 to see if I could rebuild it and use in on the Cafe. Side Note:If you followed my starter problem thread for my 83, you'll know the only reason I bought my 81 was for the starter and to have extra engine parts. I put the 81 starter in my 83 to get it back on the road and put the 83 starter on the shelf for a rainy day.

Well today was a rainy day, so to the work bench the starter went. And it didn't get much further... Next stop, the trash. :blue:

For starters, first thing I noticed was excessive amounts of debris in large chunks and shavings. Not a good sign...



Digging deeper, here's the condition of the brushes, or at least whats left of them:



And lastly, the commutator is very worn.



I'm thinking it's time for a new starter, or a rebuildable core. However by the time I find a good core, pay for it and purchase the rebuild parts, I'm probably only a few bucks shy of getting a new one. What do you guys think?

 

[canuckxxx]

For the starter the commutator could be turned on a lathe so that it is flat across and smooth so the new brushes mate up properly. Make sure the spaces between the segments are cleaned out. Then put new brushes in.

My '82 Goldwing has very good handle switches. Here is a shot of the left. The turn switch is very simple and positive snap action which goes back to the middle position easily. There is no headlight ON-OFF.

 

[93Bandit]

OK guys, I suspect a full 180* change in direction for this build. If you saw my thread in the engine section, I came across a GS750 in severe disrepair and missing some parts. A perfect candidate for a Cafe build since it was already falling apart. I made an offer on it but he sold it to someone else. So that left me really thinking about what I want in a Cafe Racer, and my GS850G just doesn't quite fit the bill. I'd rather have spoked wheels, chain drive, kick start and a few other things that my 850 just simply cannot have. I think I would end up regretting cutting it up into a cafe style, only to be not quite happy with the end result. I really want a cruiser and my 850G is already set up as one. Just needs some attention. After contemplating it and reading all the disdain for cafe builds on this site, I think I'm going to try to restore my 850G. I took a good long look at it and thought it's maybe not as far gone as I originally thought. Either way, I think a cafe build or restoring it would cost me about the same and be just as much work. So I think I'm going to keep an eye out for another smaller bike that would better fit my cafe needs and in the mean time begin putting the 850G back together. But first, what do you guys think?

Take the poll on my thread and help me decide.

 

[Steve]

I have never really seen the appeal for the cafe racer LOOK. If you are actually building a racer that actually goes from cafe to cafe (the original intent, hence the name), you are looking for a very light bike with decent power. Anything that does not enhance power, braking or handling would be removed to save weight, which also enhances handling. Starting with an 850 just blows the whole idea out of the water, because that was the heaviest GS made, until the 1100GK came along with all the touring luggage. Stripping it down like a cafe racer just puts it on-par with many other bikes in their full stock trim. Strip them down and they are even better.

Bottom line: Get the 850 up and running where it will be happy. Pick on a smaller/lighter bike for the cafe look.

When you are "restoring" the 850, feel free to do some resto-mods. There isn't much of a market for a 100-point concours restoration, so just concentrate on the safety bits (tires, brakes, controls, etc.), then make it look decent. Don't worry that you have the wrong set of switch gear for that year or any other details like that. I would have to stop and count, but there are probably 15-20 items on my bike that are "wrong" for that year and/or model. That does not count accessories like the fairing, floorboards and electrical gizmos.

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