-
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.
Kiwi Canuck tries his Luck with a Six Fiddy
- Thread starter Kiwi Canuck
- Start date
Charlie, I know how much extra work I got myself into by taking the engine apart but I was also a bit concerned about where all the oil had been coming from, there was so much build up in the front of the engine.
I think the head gasket had been leaking as I can see it was a bit damaged on the underside and all the oil between the fins which you can see in this picture.
Any comments on the piston crown, I've heard that if there is a clear ring around the outside of the top of the piston the rings are not sealing, as the outer 1/8" is somewhat clean.
Last edited:
I got a few hours in the garage today, making progress but it feels slow considering how much I've still got to do on this bike.
The weather was OK so I got the triple tree, top clamp and a few other items painted, they are now in my mechanical/boiler room as it's a nice warm place to let them dry.
One other small item to deal with was one of the studs came out when I removed the head, so I got to use the niffy little cutouts in my new Yost vise to hold the stud while I removed the seized nut and they worked really well.
I cleaned up the stud and ran a thread chaser through the engine case as well to cleaned it up, applied blue loctite and tightened it down using two nuts locked together.
I also cleaned up the pistons, about an hour in Berrymans carb dip and then a small stainless wire brush to finish cleaning up the crowns.
The weather was OK so I got the triple tree, top clamp and a few other items painted, they are now in my mechanical/boiler room as it's a nice warm place to let them dry.
One other small item to deal with was one of the studs came out when I removed the head, so I got to use the niffy little cutouts in my new Yost vise to hold the stud while I removed the seized nut and they worked really well.
I cleaned up the stud and ran a thread chaser through the engine case as well to cleaned it up, applied blue loctite and tightened it down using two nuts locked together.
I also cleaned up the pistons, about an hour in Berrymans carb dip and then a small stainless wire brush to finish cleaning up the crowns.
Last edited:
Well, I've been side tracked with sorting out my new lathe and mill that I received a few weeks ago, still waiting on a few parts to get them running but learning plenty as I go along.
Here's a couple of pictures of the delivery,
The truck driver was able to drop the machines inside the shop so they would be under cover for the night.
I went out and got a engine hoist from KMS Tools the next day to move them the last 20 ft into my little part of the shop.
I have a friend using the main part of the shop for storing his speed boat and cars as it was empty for 3 years and he is now reluctant to give up the space as he couldn't find anywhere to go, so I've agreed to let him stay for another 6 months.
I could get by with the space I have but I really need my workshop moved from the house garage to the workshop so I have just one shop as I'm already running back and forward every time I need a different tool.
It's ironic writing this as I'm sure others here are working out of much smaller places and doing just fine but when you have the space it's always seems like you can use more.
Here's a couple of pictures of the delivery,
The truck driver was able to drop the machines inside the shop so they would be under cover for the night.
I went out and got a engine hoist from KMS Tools the next day to move them the last 20 ft into my little part of the shop.
I have a friend using the main part of the shop for storing his speed boat and cars as it was empty for 3 years and he is now reluctant to give up the space as he couldn't find anywhere to go, so I've agreed to let him stay for another 6 months.
I could get by with the space I have but I really need my workshop moved from the house garage to the workshop so I have just one shop as I'm already running back and forward every time I need a different tool.
It's ironic writing this as I'm sure others here are working out of much smaller places and doing just fine but when you have the space it's always seems like you can use more.
Last edited:
As far as the GS650E is concerned, I have made a bit of progress on a few items but discovered the rear subframe is bent down by about 1" on the right side, enough to show wear on the rear fender where it contacts the tire when the suspension compresses.
I tried straightening it myself with a block of wood, a strap and a jack but it just springs back, I may have to get a welding torch and give some heat and use a chain, I have a plan so will try that.
I've treated the tank with a POR15 Kit, I followed the advice of others who posted here earlier and used isopropyl alcohol after the final rinse of the etching solution and had very little flash rust, just a minor off colour on the bare metal and then was able to get the tank fully dry with my new heat gun without any visible rust.
I also stayed on top of the final step and keep rotating the tank to coat the entire insides and also after emptying out the excess coating material.
I rotated it every 10 minutes for about 1 hr and then every 15-20 minutes for the next 2 hrs until the coating was getting slow to move, at that point I stopped as I wanted a nice finish inside the filler opening, which I was able to achieve, it's quite an involved job and I started at 5:30PM and was finished around 11PM and this tank was actually quite clean but I was concerned about a small leak in the seam near the petcock.
The tank will cure for 3 days and then I'll send it out for paint with the other parts.
I used aircraft paint stripper on the ebay front fender I picked up and once that was cleaned off, I realized how much rust was underneath the paint, so out came the trusty green 3M pads and I gave it heck until my arms were done and called it good, the painter can deal with the rest.
I have dropped the engine off at Wally Routledge's to have new rings installed along with a mild hone on the cylinders, he will also replace the valve guide seals and lap the valves and give the jugs and head a good cleaning with glass media while everything is apart.
That's about all for now, I will see if I can give an update in the next few weeks as I don't expect to get much time on the bike until the machines are finished.
I still have 2 shipments from Parts Outlaw awaiting pickup at the mailbox so until I get them there's not much I can do anyways.
David.
I tried straightening it myself with a block of wood, a strap and a jack but it just springs back, I may have to get a welding torch and give some heat and use a chain, I have a plan so will try that.
I've treated the tank with a POR15 Kit, I followed the advice of others who posted here earlier and used isopropyl alcohol after the final rinse of the etching solution and had very little flash rust, just a minor off colour on the bare metal and then was able to get the tank fully dry with my new heat gun without any visible rust.
I also stayed on top of the final step and keep rotating the tank to coat the entire insides and also after emptying out the excess coating material.
I rotated it every 10 minutes for about 1 hr and then every 15-20 minutes for the next 2 hrs until the coating was getting slow to move, at that point I stopped as I wanted a nice finish inside the filler opening, which I was able to achieve, it's quite an involved job and I started at 5:30PM and was finished around 11PM and this tank was actually quite clean but I was concerned about a small leak in the seam near the petcock.
The tank will cure for 3 days and then I'll send it out for paint with the other parts.
I used aircraft paint stripper on the ebay front fender I picked up and once that was cleaned off, I realized how much rust was underneath the paint, so out came the trusty green 3M pads and I gave it heck until my arms were done and called it good, the painter can deal with the rest.
I have dropped the engine off at Wally Routledge's to have new rings installed along with a mild hone on the cylinders, he will also replace the valve guide seals and lap the valves and give the jugs and head a good cleaning with glass media while everything is apart.
That's about all for now, I will see if I can give an update in the next few weeks as I don't expect to get much time on the bike until the machines are finished.
I still have 2 shipments from Parts Outlaw awaiting pickup at the mailbox so until I get them there's not much I can do anyways.
David.
Last edited:
S
SVSooke
Guest
You got that right
That's a bummer about the frame. I'm in the same boat, but worse since my sprockets can not be made to line up.
Not sure if anyone is still following this thread but I'll give a quick update to anyone still interested as to what has transpired in the last week or so.
I have started on the carbs as much as I don't want to deal with them, but I still haven't got the rest of the parts from Parts Outlaw and it's holding up some important pieces that need to get finished before I move onto other parts of the build.
I have both the front and rear brake calipers and master cylinders disassembled and laid out over my work bench along with a few other pieces and I don't want to disturb them by bagging them all up, so I've made some new space to start work on the carbs.
Remember this.
They are disgusting, that green sticky slime is just nasty, some of it stuck to the bathroom sink as I was taking it out of the ziplock baggy as I opened it in the sink.
It's so weird, even using Comet Cleaner which can remove almost anything wouldn't touch it, I eventually scraped it up and used a little lacquer thinners and then comet to finish it off.
The rubber bung on the pilot jet was like soft chewing gum, the main jet and needle valve were stuck solid, so 24 hrs in Berrymans and then into the ultra sonic and it's starting to clean up.
I got the needle valve seat out by using heat but somehow have lost the needle valve, hopefully it's not in the bottom of the Berrymans can, that could be fun trying to retrieve it from in there.
The 2nd carb I did was not quite as bad so after 1 hour in the ultra sonic it's looking a lot better.
I did try a new secret sauce in the ultra sonic, 3 litres of distilled water and about 100ml of Franks degreaser which I found in my garage when I bought the place 5 years ago.
http://www.prowax.com/cleaners/C-84_Franks_Special_Cleaner.html
The carbs came out quite nicely and did not darken even though I gave them three 20 minute cycles at 50 degrees celsius over about 2 hours.
The water came out very dark after just one carb and almost black after two were done, so it's working quite well.
I'll take some pictures of the progress and post them in a day or so.
I also got my big 6 foot long pry bar, and got my son to hold the bike while I gave the rear subframe heck, (I did wrap 3 wraps of duct tape around the frame to protect it) it's improved but still about an 1/8" low but didn't want to risk bending something permanently so have left it as is and will do a trial fit and see if it's close enough before I go too far.
The POR 15 tank sealer came out nicely and I need to get the parts over to the painter this week as I didn't have everything ready last week.
I did manage to break the good mirror, the nut was seized on the shaft and rather than pull out the mapgas torch and give it some heat, I just gave it a hit of penetrating oil and tried working the nut back and forth until I was able to break it off, which I did quite easily. Oh well saves me from cleaning and painting it and I'll now have 2 new matching mirrors.
Lastly, I have dropped off a few more parts to Wally Routledge to have them media blasted as I'm sort of done with manual labour cleaning up parts by hand, the brake rotors, new front fender which I stripped but he will clean it up a little more, the exhaust heat shields as one had a broken bracket that needed welding, and a few misc. other rusty pieces that I'll paint once I get them back.
More to come.
I have started on the carbs as much as I don't want to deal with them, but I still haven't got the rest of the parts from Parts Outlaw and it's holding up some important pieces that need to get finished before I move onto other parts of the build.
I have both the front and rear brake calipers and master cylinders disassembled and laid out over my work bench along with a few other pieces and I don't want to disturb them by bagging them all up, so I've made some new space to start work on the carbs.
Remember this.
They are disgusting, that green sticky slime is just nasty, some of it stuck to the bathroom sink as I was taking it out of the ziplock baggy as I opened it in the sink.
It's so weird, even using Comet Cleaner which can remove almost anything wouldn't touch it, I eventually scraped it up and used a little lacquer thinners and then comet to finish it off.
The rubber bung on the pilot jet was like soft chewing gum, the main jet and needle valve were stuck solid, so 24 hrs in Berrymans and then into the ultra sonic and it's starting to clean up.
I got the needle valve seat out by using heat but somehow have lost the needle valve, hopefully it's not in the bottom of the Berrymans can, that could be fun trying to retrieve it from in there.
The 2nd carb I did was not quite as bad so after 1 hour in the ultra sonic it's looking a lot better.
I did try a new secret sauce in the ultra sonic, 3 litres of distilled water and about 100ml of Franks degreaser which I found in my garage when I bought the place 5 years ago.
http://www.prowax.com/cleaners/C-84_Franks_Special_Cleaner.html
The carbs came out quite nicely and did not darken even though I gave them three 20 minute cycles at 50 degrees celsius over about 2 hours.
The water came out very dark after just one carb and almost black after two were done, so it's working quite well.
I'll take some pictures of the progress and post them in a day or so.
I also got my big 6 foot long pry bar, and got my son to hold the bike while I gave the rear subframe heck, (I did wrap 3 wraps of duct tape around the frame to protect it) it's improved but still about an 1/8" low but didn't want to risk bending something permanently so have left it as is and will do a trial fit and see if it's close enough before I go too far.
The POR 15 tank sealer came out nicely and I need to get the parts over to the painter this week as I didn't have everything ready last week.
I did manage to break the good mirror, the nut was seized on the shaft and rather than pull out the mapgas torch and give it some heat, I just gave it a hit of penetrating oil and tried working the nut back and forth until I was able to break it off, which I did quite easily. Oh well saves me from cleaning and painting it and I'll now have 2 new matching mirrors.
Lastly, I have dropped off a few more parts to Wally Routledge to have them media blasted as I'm sort of done with manual labour cleaning up parts by hand, the brake rotors, new front fender which I stripped but he will clean it up a little more, the exhaust heat shields as one had a broken bracket that needed welding, and a few misc. other rusty pieces that I'll paint once I get them back.
More to come.
Last edited:
J
jibledso
Guest
That's some of the most slimy carbs I've ever seen 
How did they get like that?
How did they get like that?
S
SVSooke
Guest
I for one am watching with interest. Lack of others posting doesn't mean we aren't watching.
Disassembling carbs in the bathroom sink?
You're a brave man.
You're a brave man.
Yup, here I am, working both in a tiny corner of an underground parking space, and a former village butchery. Having a lathe and mill, and a place for them, is one my dreams. Thanks for linking where you've got your machines from!
a) What sooke said and b) This thread is both entertaining and useful, since you not just document what you've done, but also how you did it. And furthermore, there is real work to be done, not just brushing off dusted pieces.
Keep it coming!
That's some of the most slimy carbs I've ever seen
How did they get like that?
The bike sat for about 30 years, I suspect they may have used stabil or some other fuel treatment and the fuel dried up and left this mess.
Greg, thanks for the support, I do these reports to keep me motivated and on task, (as well as having a record of what I've done) but lately I've been a bit distracted and a bit overwhelmed so I was wondering if anyone was actually following along and was I just wasting my time by keeping the thread up to date, apparently not, so that's good to know.
Steve, I was just unbagging the one carb I sealed in the ziploc, as it had leaked while I stored it, and the bathroom is in my house garage so not inside our home.
I do have washrooms in both my workshop and garage and they come in handy for rinsing parts with hot water and warming up paint cans before painting, I also get to cleanup before coming into the house which my wife prefers.
They are my responsibility to maintain and keep clean as the cleaning ladies don't come near them, so no complaints from anyone and I can do as I like.
David.
roeme, thanks for responding to my thread, I'm always impressed by what some people can do with very limited resources and space.
Glad you liked the Lathe & Mill info from Quality Machine Tool, there are a few guys in Europe who have purchased from them, top notch guys to deal with.
Ha ha yes there is real work, I sometimes wonder why I get so passionate about these old bikes, but I love the process almost more than the results, even if I find myself in overwhelm on almost every project I've taken on.
David.
Last edited:
I check the forums pretty much every day. There's a few rebuild threads that I look forward to seeing updates on, even if I don't really have anything to say. This thread is one of the ones that I get excited about seeing progress in.
I have a feeling there are a lot of people like me following along.
Sam thanks for commenting, it's nice to know you are following along and find what I post interesting.
I should have a bit more of a substantial update to my rebuild shortly if I can get some parts here.
Cheers,
David
Thanks Charlie, I have 2 carbs done and working on the 3rd one, thank god these were not the first ones I tried to rebuild, it would have put me off for life.
David.
Here's a few pictures of the carbs as I clean them up.
One of the carbs before cleaning,
![IMG_3894_zpsd3xtozmy.jpg](http://[URL="http://s1071.photobucket.com/user/KiwiCanucker/media/IMG_3894_zpsd3xtozmy.jpg.html"][IMG]http://i1071.photobucket.com/albums/u508/KiwiCanucker/IMG_3894_zpsd3xtozmy.jpg)
[/URL][/IMG]
The tools I use for disassembly, I use mostly new screw drivers just for the carbs, as they need to fit perfectly to avoid the driver caming out when removing the jets and causing more issues.
I needed to use heat on the needle valve seats to loosen them as the rubber o-ring had glued itself together into kryptonite.
![IMG_3898_zpsxqic440h.jpg](http://[URL="http://s1071.photobucket.com/user/KiwiCanucker/media/IMG_3898_zpsxqic440h.jpg.html"][IMG]http://i1071.photobucket.com/albums/u508/KiwiCanucker/IMG_3898_zpsxqic440h.jpg)
[/URL][/IMG]
The ultra sonic 3l capacity.
![IMG_3900_zpsp6vzuj9g.jpg](http://[URL="http://s1071.photobucket.com/user/KiwiCanucker/media/IMG_3900_zpsp6vzuj9g.jpg.html"][IMG]http://i1071.photobucket.com/albums/u508/KiwiCanucker/IMG_3900_zpsp6vzuj9g.jpg)
[/URL][/IMG]
A couple of carbs, one on the right is complete, the one on the left still needs another cycle through the Ultra Sonic bath.
![IMG_3901_zpsvidb4iws.jpg](http://[URL="http://s1071.photobucket.com/user/KiwiCanucker/media/IMG_3901_zpsvidb4iws.jpg.html"][IMG]http://i1071.photobucket.com/albums/u508/KiwiCanucker/IMG_3901_zpsvidb4iws.jpg)
[/URL][/IMG]
One of the carbs before cleaning,
The tools I use for disassembly, I use mostly new screw drivers just for the carbs, as they need to fit perfectly to avoid the driver caming out when removing the jets and causing more issues.
I needed to use heat on the needle valve seats to loosen them as the rubber o-ring had glued itself together into kryptonite.
The ultra sonic 3l capacity.
A couple of carbs, one on the right is complete, the one on the left still needs another cycle through the Ultra Sonic bath.
Last edited:
One other piece of good news was I got a used turn signal from my local Suzuki dealer for $15.00, not sure what it was from, but saw it in a used bin when I was picking up some for oil for the forks.
I was able to switch out the short stubby extension for the longer ones used on the GS650E, and the piece I needed was in great shape, I reused the original lens as well as it fit better and the colour was same as the others.
No pictures of the turn signal but here's the oil I got, 15W as recommended in the manual.
A bit rich on the price but I like to support my local guys when I can and thankfully I didn't have to pay full retail for it.
I was able to switch out the short stubby extension for the longer ones used on the GS650E, and the piece I needed was in great shape, I reused the original lens as well as it fit better and the colour was same as the others.
No pictures of the turn signal but here's the oil I got, 15W as recommended in the manual.
A bit rich on the price but I like to support my local guys when I can and thankfully I didn't have to pay full retail for it.
Last edited:
