trying to get my 82 650 back on the road

[orangechicken007]

Hey guys,
Lately I've been working alot but ive been able to get a few things done.
Clutch cover cleaned and a new gasket. The P.O. used black gasket sealer and just put it on top of the old torn gasket. took awhile to get both surfaces clean but they are now and have a new gasket.
Head gasket and half moon seals replaced. cleaned both surfaces well and it seems i have a good seal.
Bike starts right up now on Choke but i think I will need to ajust the mix screws again.
I moved onto the front forks which were a huge mess and had a few questions
I was able to get the fork oil to drain and ive removed the old rubber seals but i can get the forks to open up. all they will do is spin. I looked at my manual and i have a little different set up than what is shown in their.


when I put a socket on the thing it just spins. any ideas?
Also what is the best way to clean out the mufflers/exhaust? Im thinking for sitting so long they probably have quite a bit of dirt setting in them

 

[BigD_83]

IIRC, there should be a circlip that holds the works together.

 

[tom203]

Yes, there is a circlip. My 81 had just a plastic cap at tube top, but parts fiche shows the 82 gl with nut.
To OP , does your setup appear to be like this parts layout?

http://www.alpha-sports.com/spst/1982 GS650GL/22.htm?q=suzuki-parts

 

[orangechicken007]

it appears similar, but beneath my air valve there is just a washer, nothing else. and when i turn the air valve it just continues to spin, where would the circlip be?

 

[tom203]

it appears similar, but beneath my air valve there is just a washer, nothing else. and when i turn the air valve it just continues to spin, where would the circlip be?

The thing that you think is "just a washer" likely has a small step in its outside rim where the circlip (part #27) hides. Push down hard on center of "washer" and you will likely see it!

 

[mnferwerda]

Yes, press down hard and you will see the clip. You'll need a pick to get it out of the groove in the fork tube. It might be easier to have a friend push down on the cap (since the fork spring is directly below it). At least yours is not rusted. Mine was a mess and had to put a lot of penetrating oil to get it loose.

 

[orangechicken007]

Hey guys, thanks for the responses, the forks are all back together and on the bike. now I am cleaning out the Gas tank and working on the brakes.
Im having trouble getting front brake to release. When pump the piston out it looks like it is in great condition, no rust scoring etc. ive also bled the brakes and added new brake fluid.
Should I buy a rebuild kit or a whole new caliper? how much pressure should it take to push the piston back into the caliper? it goes in easily with a C-clamp but I cant push it back in with my hand.

On the back brake I went to bleed all the old fluid and I got one good pump and some old brown fluid out and then nothing. it wont build up any kind of pressure. Im guessing that this means that pump will have to be replaced correct?

Thanks again guys for all your help and insight.

 

[jeff13m]

Rebuild. Even if you buy upgrade caliper, unless its new, I'd change the seals and o-ring at the very least. it's not that hard or time consuming - check you tube or search here for info. Parts should be under a hundred bucks total. Get oem stuff.

 

[orangechicken007]

well its been awhile,
quick catch up,
sorted through the brakes, carbs(disassembled, dipped, new rings), replaced intakes, fuses, and lots of other little things. its been inspected and is all legal and I've been able to start riding it around town. been a blast starts right up, it idles well, right between 1000-1100, all my electrics seem to be working well. no problems at all in town.
However, once I started to feel confident in its reliability I started taking it on longer runs out of town and heres what I noticed.
it accelerates fine, shifts fine, but in 5 around 6500 rpms it levels out. I can lay on it and open it all the way up but it won't get over 7000 rpms, in 4th I managed to get it to 7500 ish but it still is like hitting a wall. when its held all the way open it will lurch, thats the best way I can describe it, like its trying to go faster but Its missing something. speed tops out at about 80, which isn't bad if I was going to be riding it in town, but for highway riding it would be best to have a little more speed to get out of trouble if I need to.
My first thought was fuel starvation.
I recently put a new fuel lines and made sure it wasn't kinked, vacuum hose isn't kinked, petcock is new, tank has been cleaned very recently, I checked the cap and I think its fine, What else should I check? I'm running out of ideas.

 

[orangechicken007]

went from 110 main jets to 115 and it made a huge difference, topped out the speedo (85 mph). what kind of speed are you guys getting on the 650 ? my acceleration is much better in 4th than 5th is that normal? I want to get it tuned up as best I can