82 850GL Resto...here we go

[lmrmllr89]

I just ordered the 3 pc motorcycle set..... From this place.....haven't got them yet
http://www.rjrcooltools.com/shop_item_detail.cfm?subcat_ID=138

 

[Good Times]

Haven't posted in a little bit because I've been doing "project support" over the last couple of weeks. I realized quickly that I was spending more time looking for tools than I was working on my bike. So I did this:

Then I realized that I didn't have a good place to work on parts like carbs, gauges, and other smaller bits. So I made this:

My wife also let me know that it was time to get her car back in the garage. So I bought a bike jack. Figured it would make easy work of moving the bike around and the motor once I've pulled it. So I purchased one and when it came in the mail the hydraulic ram looked like this:

I have to take this opportunity to say that the company (discountramps.com) did a phenomenal job taking care of me. This picture was taken at 8:30 at night. I emailed them shortly after and the next morning by 9:00 I had an order confirmation for a new jack in my inbox. I got it three days later and sent the broken jack back today. That's a company that stands behind their product and handles thing very positively. Kudos to discountramps.com!

So with my new jack, work bench and some other tools (JIS screwdriver set and float gauge) in place, I got back to it this afternoon.

Removed the windshield.
Finished labeling the wiring harness.
Took pictures of everything and some video as well so I have a chance of getting it back together correctly.

Then the carbs came off:

I knew that the #1 bowl had been leaking so I inspected it after removal. I was not pleased to find out that a PO had stripped the screw and just put an additional rubber washer on it. It was just barely hanging in there. The bowl is stripped, not the screw. hmmm.... New bowl our bigger screw?

Then it was time to check the intake boots & o-rings. I was glad to see that the screws came out very easily. That's one the a PO did right. Lots of anti-seize on the screws! Yes. No impact tool needed.

The boots looked good at first. Still pretty pliable.

The o-rings were another story. Flat as a pancake.

After getting the boots off and a little closer inspection, number 2 was a lot harder than the rest. There is also a lot of the rubber chipping around the edges. I think I will go ahead a replace them. Better safe than sorry.

Ok, so here's my question for the night. How do I get the clutch cable off the crankcase? I back the adjustment screw all the way out after loosening, but the spring doesn't easily come out of the space in the top of the "holder" on the case. What am I missing? Instead of forcing it out and messing something up I thought I'd post a pic and ask for help.

Here's the bike as it sit right now.

 

[Guest]

Mate I'm just checking your thread out for the first time, good to see you progressing!

Nice work with the tools, I had the same problem during my rebuild but still haven't done anything about it yet. We're currently doing a spring clean in January so the garage will be done in the very near future, and your wall of tools has given me some excellent inspiration...

As for the carb bowl, I'd probably get another one as repairing that soft alloy would be a bit difficiult I would think.

Definitely replace the carb boots on the head too. I thought mine were ok but the difference between them and new ones was night and day. I had to use rubber grease to get the carbs in and out with the old ones, the new ones they just slide right in and seat themselves.

The rubber shrinks over time, which means hard to get carbs in, and the clamps don't do a good job of clamping.

 

[Good Times]

Thanks Pete! It is really great to be able to find what I need when I need it. I'm glad I took the time to get organized.

After I laid down last night I figured out the clutch cable. Duh, take the other end loose and it should come right off. That was the first thing I did this morning and off it came.

I spent time today getting electrics off the bike and the wiring harness pulled off the frame. I moved pretty slow with this part of the deal. Trying to be deliberate and learn the bike as I tear it down. I'm labeling anything that isn't obvious and boxing the parts up as they come off. I removed the foot pegs, crash bars, and some other bits and pieces. Drained the oil and gear oil. Learned that instead of replacing the o-ring on the oil filter cap that the shop that changed the oil for the PO use some sort of sealant. Got that cleaned up and will be ordering a new o-ring.

I was about to pull the motor and got to the drive shaft. I realized that I would need a metric wrench to get the bolts off. That's where I stopped. I'll pick up a set of wrenches tomorrow after church.

The goal is to get the motor pulled tomorrow. It's coming along.

 

[Good Times]

Went to Lowes after church and picked up a set of wrenches and some screws to see if I could make one work with the stripped float bowl.

Back at the Bat Cave:

I should have shot a time lapse video of me trying to get the motor pulled by myself this afternoon. It would have been quite hilarious to reach. I figured hey no sweat, I'll just take the mounting brackets off lay it over and the motor should just slip right out. That did not turn out according to plan. Finally with a little brain power, elbow grease and the right jacks I managed to accomplish this:

That was the lions share of what I did today. It took alot of trial and error, mostly error, but even a blind hog finds an acorn once in a while.
It felt good to get that motor pulled. I'll start getting it cleaned up next.

Next it was on to the float bowl. As you can see in the pic, number 1 is stripped and has been leaking.

I could only find 10mm bolts, but a little work on the grinder and I had this:

The new bolt bit and seems to have worked. Doesn't look perfect, but I don't think anyone will be looking under my float bowl.

Good day in the garage.

 

[Guest]

Good job Goodtimes. Feels good to have a good day wrenching huh? You get to ride some beautiful roads over there in KY. And yeah, next time you try and wrestle an engine out like that you have to video it. We could use a good laugh hehe ;-)

 

[GateKeeper]

not sure if you have or have not, but strip down the carbs completely, clean em really good, and get the O ring kit here - http://www.cycleorings.com/

he has the O rings for the boots as well and some nice SS bolts

nice progress so fare on your rebuild....

 

[Good Times]

Good job Goodtimes. Feels good to have a good day wrenching huh? You get to ride some beautiful roads over there in KY. And yeah, next time you try and wrestle an engine out like that you have to video it. We could use a good laugh hehe ;-)

It truly would have been hilarious! I won't be doing that again though. I'll look like pro next time. Going to try to get this project wrapped up so I can ride those roads when it gets warmer!

not sure if you have or have not, but strip down the carbs completely, clean em really good, and get the O ring kit here - http://www.cycleorings.com/

he has the O rings for the boots as well and some nice SS bolts

nice progress so fare on your rebuild....

Yes GK, I have plans to tear them down completely clean them and even check the jetting to be sure it's correct for the pods and 4 to 1 V&H pipe. I will be getting everything he offers at cycleorings.com.

 

[Guest]

Nicely done on getting that float bowl sorted! I thought you'd have to source another one for sure but that's a much better solution

 

[Good Times]

So tonight we started the Simple Green clinic. His and hers bottle brushes and we were all three off to the races.

We just concentrated on the back of the crankcase and the oil pan. I think we got off to a good start.

Best part of the night was hanging out with the kids. Had some good conversations around that 30 year old grease ball of a motor.

Good Times

 

[downsy]

Greetings from down under , I am enjoying your rebuild soapy with pictures very much
Reminds me how much hard work it is to pull the thing apart, and even harder to put it back together, always have some bolts left over !
Well done on the job so far and look forward to your future episodes

 

[Guest]

Mate that's looking nice and clean

 

[Good Times]

Here's the next episode Downsy:

I had about an hour and a half tonight to break out the simple green again. My daughter and I hit it for a little while and had a good time doing so, although she did tell me that the air compressor is too loud.

I removed the starter cover to find leaves around the starter and the space behind the starter. Not that big of a deal other than the fact that I had the number one carb leaking down onto those leaves which were stuffed around the wiring. Smokey the bear always told me that "only I could prevent forest fires" and here I am about to start one.

Here's what it looked like before we started cleaning:

Once I blew the leaves out I found these in there as well. I am pretty meticulous about labeling every part that comes off so I'm not left with extra parts when I'm finished, but what do you do when you find parts buried under leaves on the crankcase? No fair!

I found these under the leaves. Socket and bolt. They've been there a long time. The socket is packed with grease and grime.

I removed the stator. It's fried. Then fashioned a plug for the starter hole in the case. That will allow me to clean without getting water in the crankcase.

This looked pretty good:

Before:

After:

We're getting there slowly but surely. I've got to start making a parts list. Lot's of little things that I need to remember when I go to purchase parts.

I'll be back at it tomorrow for a little while. Until then...

These are the days of our lives.

 

[downsy]

Thanks goodtimes very enjoyable don't you just love the things you find when you start pulling these old bikes apart !
I look forward to tomorrows episode !

 

[Good Times]

More scrubbing.....

Started on the front of the motor today, the toughest part. The tach drive had been leaking for a while and all of that oil was baked onto the front of the motor.

Before (picture doesn't do it justice, it was nasty):

After:

I used up a lot of elbow grease today. It's still not like I want it but I am chipping away at it.

Pretty sore from all the scrubbing. I dropped my spoon full of stew tonight on the table at dinner. Everyone thought that was pretty funny.

 

[downsy]

It's hard work cleaning of all that baked on crud ! Looking good !

 

[brslk]

More scrubbing.....

Started on the front of the motor today, the toughest part. The tach drive had been leaking for a while and all of that oil was baked onto the front of the motor.

Before (picture doesn't do it justice, it was nasty):

After:

I used up a lot of elbow grease today. It's still not like I want it but I am chipping away at it.

Pretty sore from all the scrubbing. I dropped my spoon full of stew tonight on the table at dinner. Everyone thought that was pretty funny.

That before pic looks a lot like mine looks. Did you fix the tach drive leak?

Bruce.

 

[Good Times]

I haven't fixed it yet. I have the oil band and sleeve but am planning on replacing the case gaskets and fix the tach before I paint it. Just trying to get it clean so I can paint it later. I think I'm about to try some paint stripperr on the motor next. I'd like to get it as close to metal as I can.

 

[Good Times]

Still at it! I've just been posting up in the other forums to tackle some issues. Here's everything in a nutshell.

http://www.thegsresources.com/_forum/showthread.php?t=187350

http://www.thegsresources.com/_forum/showthread.php?t=187537

In the meantime I fixed the tach drive and received this in the mail and will be putting that to good use as soon as I locate the right material to plug my ports.

 

[Good Times]

I think I have her all sealed up and ready for soda blasting tomorrow. Lots of trial and error on finding plugs for the ports. I finally bit the bullet and bought the test plugs. I bought 4 and plan on blasting the exhaust side with them in with the intake ports taped and then switch them when I blast the intake side. I'll have to clean up before the switch, but those plugs aren't cheap.

Sheetrock anchor wrapped in electrical tape. Tapped it in then put the screw in.

Ready to go!