BassCliff GS850GT Top End Refresh

[BassCliff]

Hello friends,

I spent a little time in the "man cave" today getting ready to replace gaskets, rings, and other assorted bits in the top end of my "Jessie".

Here's where we start. (Pretty good looking old bike, eh?)

The airbox had actually started to slip away from the carbs. I imagine I had a slight air leak as at least three of the airbox boots were loose.

Tank, seat, battery, and side covers removed.

Airbox removed. You can see one of Jessie's oil catching pads there on the base gasket.

After removing the top two bolts holding the airbox it just fell out. I guess the boots were really loose. Oops.

Next, the carbs came out. They were still really snug. You can also see the other oil catching pad at the head gasket on this side.

Intake boots removed.

After loosening up the jam nut a little on the cam chain tensioner, it was removed.

That thing is filthy. I'll be rebuilding it too.

Just a couple of shots to show you where the main spring sticks into the knurled knob and the body of the tensioner.

A few more pictures in the next post.

Thank you for your indulgence,

BassCliff

 

[BassCliff]

Hi,

I'm trying to stay organized.

I've collected a lot of Altoids tins and I find them handy for keeping all those little bits organized. Keep the clamps, screws, etc, for each sub-assembly all together. From left to right you see the airbox clamps and bolts, the intake boot clamps and fasteners, the cam chain tensioner and bolts, and the highway bar bolts.

And here's where I left her until next week, if not sooner. I'll start on the valve cover and work my way down.

I didn't bother to set #1 cylinder at TDC when I removed the cam chain tensioner. I figured since I'm taking the cams off anyway that I can get it all lined up and timed later during reassembly.

This is going to be fun!


Thank you for your indulgence,

BassCliff

 

[tkent02]

Hey Cliff,

What are you riding while Jessie is down?

 

[posplayr]

I sense another great tutorial in the making

 

[BIG_brother]

This for fun or was she getting tired?

 

[Guest]

Subscribed. I remember seeing your bike for the first time at Bruces and took a keen interest in your remedy for oil loss, I've shared that tidbit with many a new biker that I've met I'm guessing this one will be added to you site when you're done Cliff. I'm a fan of Altoids as well.

 

[Good Times]

Excellent. I love that you are doing this. I will have to do this same thing on my bike one day, but not today.

 

[1980GS1000E]

Cliff, I echo what tkent02 said- I wanted to go riding with you guys this summer since we didn't do a ride last year. But it's good to get Jessie all fixed up.

 

[Badooka]

BC- your Awesome and that bike looks great- but if those parts were in ALtoids tins where I have worked, other mechanics would have used blunt force trauma on me!!!!!

 

[BassCliff]

Hi,

This for fun or was she getting tired?

Over the last couple of years it had developed a couple of oil leaks that just kept getting worse until I finally decided to buy a gasket kit and replace everything from the base gasket up. I'll also be replacing the O-rings in the carbs, clutch springs (there has been a little slipping), rebuild the cam chain tensioner, and just generally freshen everything up.

It's been running great at 65,000 miles. I was hoping to put this off for another 20,000 miles or so but I got tired of oil on my boots and pants. I ride about 10,000 miles a year so I want to get it all done right while it's down. I'm sure this is going to take at least a couple of weeks between my three jobs and family. But it will be fun. Stay tuned. Thanks for watching.

No, I don't have anything else to ride while Jessie is down. I've got a friend or two in the area who I'm sure would lend me a bike but I don't want to ask and I would not accept if they offered. As long as I'm not riding it will be incentive to hurry this project along as much as possible. Commuting to work in my Astro van takes over $50 a week and I can do it for less than $20 a week on Jessie. So there's a financial incentive too.

Thank you for your indulgence,

BassCliff

 

[cowboyup3371]

Looking forward to watching you work on yours.

 

[Steve]

I sense another great tutorial in the making

Hope he manages to submit it to that rock-n-rollin' librarian guy that maintains a "little website". :-\\\

I wonder if he is referencing that "little website" during the rebuild? :-k

.

 

[GelandeStrasse]

Watching this thread with keen interest! Thanks for posting.
What material are the oil catch pads made from Cliff?

 

[Dogma]

I like the idea of keeping related bits together. My 1000's top end is in disposable sandwich-sized tupperware tubs while I wait on correct orings.

 

[Eli69]

my first thought was, "why didn't he do this over the winter?" hahahahaha

what winter, right californ-i-a?

 

[BassCliff]

Hi,

my first thought was, "why didn't he do this over the winter?" hahahahaha

what winter, right californ-i-a?

Really. I rode all winter. I've put this off until I can't put it off any longer.

Not able to work on it today because I'm still at my Dad's house fixing his computer. Oh well. All in good time.


Thank you for your indulgence,

BassClif

 

[Eli69]

sometimes i have to think outside of the box and remember that some folk don't get 100" of snow each year. good luck on your rebuild and here's to not finding any unpleasant surprises.

 

[BassCliff]

Hi,

What material are the oil catch pads made from Cliff?

I've used various linen-like paper hand towels...

http://www.cleanitsupply.com/p-5272...en-like-paper-towels-800-towels-gep92113.aspx

...or shop towels...

But my favorite are the Pig Pads, very absorbent. I cut them into strips, roll them up, and stick them between the fins.

See: https://us.vwr.com/store/catalog/product.jsp?product_id=4648366

Our very own Mr. renobruce introduced me to Pig Pads.


Thank you for your indulgence,

BassCliff

 

[barnbiketom]

sorry you have nothing to ride but I know you'll take your time anyway!!!!

that bike has no problem leaking oil.. it's old enuff eh???

time for a freshen up and hope you get thru it with no issues!!!!!

 

[BassCliff]

Disassembly Complete

Disassembly Complete

Hey guys, I'm back.

We remember the high price of our freedom. Today I spent my freedom in my garage tearing down the top end.

I started with the exhaust, removed the rear bolts.

Removed the three bolts holding the crossover to the oil pan, two of them seen here next to the oil drain plug.

And removed the header bolts.

Loosened the clamps on the crossover.

And pulled the two middle headers out.

After removing the middle headers I dropped the whole exhaust to make it easier to disassemble.

After loosening all the clamps it took a little persuasion to remove the crossover.

I think I may have to replace these rubber grommets for the mounting holes on the crossover. They're pretty deteriorated.

The exhaust was disassembled and hung on the wall.

Now it's time to start at the top and take everything off down to the base gasket. We begin with the breather and valve cover.

Lots more pictures. To be continued.

Thank you for your indulgence,

BassCliff