GS650L Daytona bar swap, a couple questions

[exzachtly1]

Swapped out my stock L bars for black Bikemaster daytonas (and oury grips) yesterday. Easy peasy, but I am of course facing cable length issues that I am working through re-routing. I know that topic has been discussed many times and I have plenty of ideas for fixing that so I'm not gonna go there.

However, what I have not often seen discussed is two things -

What does one do about the now somewhat awkward angle of the master cylinder? Is it a problem to have it at that angle, or should I consider replacing with a different model? Obviously on the side stand the angle would be much worse...

I also noticed that my choke cable is having big issues now. It doesn't like having the new slack in it and seems impossible to pull no matter where I put the extra slack. I guess I have to re-route the choke cable to get it as straight as possible also?? Most people with similar threads don't mention this.

 

[exzachtly1]

Oh and here is a before, after from my POV sitting on the bike Don't pay attention to things being maladjusted, I'm not done yet

 

[tom203]

You still got single front caliper? I wouldn't worry. My setup is similiar to your "after" pic but my master cylinder has a round reservoir, but it's tilted also.
I've seen alot of 650's ,but never saw any bars like your before pic ones-they are pitiful- if they were stock, seems everyone around here lost them. My choke cable passes thru triple tree, so I can't help you. Obviously, you could take cable off and measure and head to shop to find shorter one - for choke, aftermarket should be OK

 

[exzachtly1]

You still got single front caliper? I wouldn't worry. My setup is similiar to your "after" pic but my master cylinder has a round reservoir, but it's tilted also.
I've seen alot of 650's ,but never saw any bars like your before pic ones-they are pitiful- if they were stock, seems everyone around here lost them. My choke cable passes thru triple tree, so I can't help you. Obviously, you could take cable off and measure and head to shop to find shorter one - for choke, aftermarket should be OK

Thanks tom. Yes, single front caliper and yes those were the stock bars. Pretty terrible no?

I just got done messing around trying to re-route the cables and I'm not too happy with the situation... clutch cable wants to bind when I turn the bars left. I re-routed it to the other side of the frame and down through the original location between carbs 1 and 2; length is good but I don't like how it passes right under the petcock and binds up a bit when I turn the bars left.

Choke cable, I discovered is totally frayed where it connects at the handle bars.

SO it appears I need a new choke cable. I also tried removing it from the carb end, but the ball end of the cable got stuck in the little brass tube that guides it to the choke mechanism. I'm not sure how that's supposed to come out when it comes time to replace.

Finally, the throttle cable was binding and revving the engine when I turned the bars left with the bike on. So I have to investigate re-routing that as well.

At this point I just want to buy all new cables but am pretty uncertain which ones will work. Ed (Nessism) mentioned GS1000S clutch cable, 1980 GS1000S or 1982 GS550M throttle cable in this post but that is for an 82 850L which appears to have different clutch and choke cables from mine.

1982 GS650GL fiche
1982 GS850GL fiche

I would just measure them but I can't fine cable lengths listed anywhere. So not sure where to start.

 

[exzachtly1]

And I would get the throttle cable off one of the bikes mentioned, since it should work, but the part is not available on G&S suzuki or boulevard suzuki for either bike

Edit - it is available via motionpro. So I will do that for the throttle; still not sure about clutch or choke (unless I just get the same choke cable).

 

[exzachtly1]

Searching around it looks like mayyyyybe an 83 GS650M might have the right clutch and choke cables... but the parts don't look quite the same on the fiche. Can anyone confirm?

 

[rockhammer]

I am just going to go with new cables and brake lines on mine. The cables and lines are old any ways. Although they still work I think they should be upgraded. Keep us updated on your progress. I am interested in seeing your results.

 

[rockhammer]

I have not actually looked for the new cables yet so I can t really help there. I am interested in learning what you find however.

 

[BigD_83]

Searching around it looks like mayyyyybe an 83 GS650M might have the right clutch and choke cables... but the parts don't look quite the same on the fiche. Can anyone confirm?

I have to check, but I believe I went with a 650M throttle cable on my 650G with european touring bar. It was a tad tight, but eventually I found a routing that did not bind.

 

[exzachtly1]

I have to check, but I believe I went with a 650M throttle cable on my 650G with european touring bar. It was a tad tight, but eventually I found a routing that did not bind.

I am weighing that option too... right now I think there are 2 alternate bikes that might be options, either an 82 650 (E or G), or the 83 Katana. But I am not sure about compatibility with the Katana because the parts do look slightly different in the fiche (look at the connector on the engine side of the clutch cable, for example).

1982 650GL
Clutch: 58200-34X03
Choke: 58410-47X00
Throttle: 58300-45221

1983 650M
Clutch: 58200-34X02
Choke: 58410-45X00
Throttle: not available

1982 GS650E
Clutch: 58200-34X00
Choke: not available
Throttle: 58300-44232

Does it look like the clutch and choke cables would work off the 650M? The part numbers only vary slightly. Looks like a matching choke cable might be my only option since motion pro doesn't seem to make them any more, the M doesn't match, and the E is not available.

Sigh... things are never easy though I am close to just going with the G or E cables, even though they might still be slightly long.

 

[exzachtly1]

Doing more research... and it looks like the 82 GL, G, and E all use the same cables in motion pro world. Both the motion pro site and Z1 list them as being the same cable for all 3 models.

Scratch that option!

 

[exzachtly1]

I went ahead and ordered a stock choke cable, i know that can be re-routed easily with no issues.

Also ordered a motion pro throttle cable for an 82 550M. It was only $9.00 at bikebandit, so no sweat if it doesn't work out. Will just have to figure out re-routing if it doesn't :dancing:

Clutch cable, I'm still at a loss. I'm going to mess with it again when I get home and see if I can find a better routing. I suppose I can just do what others have suggested and route to the outside of carb 1 rather than in between 1 and 2, but I don't like how it just hung out there with that routing... it also looked like it would rub against my side cover and probably scuff it up eventually. Boo.

 

[BigD_83]

I don't recall exzachtly, but I think the GS1000S clutch cable works as well. I think there is a thread that addressed that question.

 

[exzachtly1]

I don't recall exzachtly, but I think the GS1000S clutch cable works as well. I think there is a thread that addressed that question.

Thanks for the suggestion. I've seen that mentioned in quite a few threads (like this one); but the problem is that many of the guys going that route are on 850s which appear to have different connections at the clutch release arm side...

Easiest way to see it is on motion pro's site. Here is the cable off an 82 850G:

And here is the cable off my bike, an 82 650GL:

Maybe a little hard to see, but the GL cable has a screw that goes straight into the end of the cable. So I don't think these can be interchanged. I also looked at the parts fiche for the clutch, and they have different part numbers for the clutch release arm.

It's looking like a custom cable might be the only choice if I can't re-route, which is OK I guess. Seems like it's 40 bucks to do which isn't too terrible. Just have to figure out how long it needs to be and order one up.

Unless anyone has any other suggestions of a bike model that might work out for this application...?

 

[exzachtly1]

Upon closer inspection it looks like the cable off an 83 GS650M might work... the clutch release arm has the same part number... hmmmm

 

[exzachtly1]

Got my new cables in the mail, and here are the results.

Throttle cable is about 7-7.5" shorter. This is the motion pro one for a 82 GS550M. I installed it and it worked out great, if just a tad tight. For a minute I thought it might be too short but it worked out prefectly.

I also got a clutch cable, pictured in my previous post. This one was off an 83 GS650M. I was surprised to find that it was only about 3.5" shorter than mine

I was a little bummed about this because I'm not sure if that's enough to make a difference... I don't think it will be able to follow the stock routing. So for now I am leaving the stock one on to see if I can deal with it. It's OK but definitely rubs a bit when you route it to the right of the steering stem like I have it now.

For the choke, I used the stock one and re-routed it around the right side of the steering stem, through the right frame cover, and down. There's still a bit of slack up front but it doesn't affect functionality.

I tested the throttle through the full range of steering and couldn't feel any issues.

Now, if I could just take care of these broken exhaust bolts and get my new exhaust on so I could RIDE. But that's another thread entirely.