• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Friends new bike. What started as a tune up......

  • Thread starter Thread starter sharpy
  • Start date Start date
S

sharpy

Guest
Bike was nice but didnt run due to no fuel and carbs needed tuning but he brought it anyway as it was looking pretty nice. 5 hr drive total trip to pick bike up. Few days later was my time to have a look and do a tune. Sorry about pics not being here but carbs where 1st item. Had to use spares from the parts bin as 2 air screws had the tips broken off and little things like that. They seem fine now but havent run them yet.

 
Last edited:
Now the fun started

Now the fun started

Tappet cover off and visual inspection. It had 2 kawasaki shims biend used. Floating around on top of the buckets as there from memory .5mm smaller in diameter. Was decided to pull the head off as 4 bolts where stripped and was a mixture of genuine bolts and hardware bolts on the tappet cover AND cam caps. You can see what ones marked in red where stripped....



Also the tacho drive had its mounting tab broken so was just sitting in there but interference fit....

 
But wait theres more

But wait theres more

Sorted the threads and stuff i checked the clearance and all was fine untill u tried to do a quick test of shim sizes on the bench. With cams bolted in and clearance checked all seemed to be fine........



Untill i tried rotating the cams. Even with just one cap on and only two bolts nipped down the cams where almost impossible to rotate. After discussions with owner it was decided to get another head from a mate and playing round with caps and fully sorting new helicoils was too much drama.
 
Not out of the woods yet.......

Not out of the woods yet.......

The other head arrived and i noticed welding on the cam caps but was more surprises inside........



Not going to say much in this but you can see what i saw when pulled the caps off.....




 
Dont ask me why they welded the caps as i had to linish the weld to let them rotate in the head. All seems fine now and but then i did a boo boo. Broke the top of the valve guide off removing the seal and pulling the head apart.



But that was ok as had to get the valves done. Well i said it was ok, still a stuff up.
 
Now to rest of the head....

Now to rest of the head....

All apart and all clean and you could inspect it lots easier. Fliiped it over and the valve seats shouted out, Hey Sharpy look at me....




Main reason i never take my head to a car (or) bike person unless i know them personally. Fully sunk valves explained the small shim clearances. Trouble is one side was high shim numbers, other side was low shim numbers. That and a valve tip that was on a angle didnt help much at all. Head is all sorted now he says with a few guides in and hoping he is correct about that.
 
Then we paid attention to rest of bike as it was thought a good idea to do the rings on what suppose to be a fresh set of pistons. Off comes the barrel and put on bench. Guess what, more surprises....



Cracked fins...


 
You sick of my pics yet? But wait theres more.....

You sick of my pics yet? But wait theres more.....

Behind the ignition cover.......



Clutch cover.....



And starter motor cover....

 
Then there is this.....

Then there is this.....

Steel plate that was running on the out plate, odd number of steel versus Fibre plates...



But thats ok as the spring in the clutch are all loose. well the two that have washers installed seem fine
 
Still pulling apart but run out of pics (for now)

Still pulling apart but run out of pics (for now)

We know the starter gear is hanging on by 3 loose allen bolts and the sump was filthy dirty, but pulling the engine out by the weekend too see whats inside the lower cases. FYI. Most Cam chain tensioners and guides are cracked and hoping the crank end on the alt side is good condition. Have a parts engine sitting there on stand by. Whew this is one tough tune up. lol
 
Not sure if true but local guy in Lismore, Australia did the head work/fitment but bike was gotten from New Zealand
 
You must log in or register to reply here.

Similar threads

NateDogg83
Old Bike, new rider, same ol' problems - 1980 GS550E
Replies
17
Views
347
gtem
gtem
J
Not Brand New, But New
Replies
5
Views
126
JPRICE91990@GMAIL.COM
J
cdahl383
First road bike - 1982 GS550L
2
Replies
26
Views
614
cdahl383
cdahl383
cdahl383
GS300L starts and idles but bogs with throttle
Replies
17
Views
314
salty_monk
salty_monk
aflythe
1981 GS850glx (BS32SS) Air screw/tuning help needed!
2
Replies
20
Views
402
aflythe
aflythe
Back
Top