Wife's new bike, GS850GL with a 1000 engine

[bomber737]

More polishing and more polishing and more and more and now I am done and or I give up. Spent 6 hours working these 2 pieces and the final step was using my dremel to get in the small crevasses for a final polishing. I think I will go tomorrow and buy some more mothers, mine was so old it had separated.

I will have to find another sticker for the stator cover. The one that was on it came off when I started to polish it and I actually managed to polish away a few of the letters. Fleabay here I come..

 

[eil]

Looking good, can't wait to see the final product.

 

[Wraith]

Looking very nice and shiny

 

[bomber737]

Thanks guys I have really enjoyed watching all your bikes get reborn over the last few years. I got my garage heater hooked up so no more freezing my a$$ off working on this thing. Wife was over tonight and picked her handle bars so now I am just waiting for the new clutch perch and front master cylinder and I can get the top end done for good. I also found more stuff to polish while I wait so off came the exhaust mounts and off to the polishing wheel I went. I think they look great and should look great when I start working on the exhaust.

One of the mufflers had a small hole in the bottom so I will have to get that welded up before they go on. Other than that they are in great shape. I still do have a bunch of exhausts left over from the 30 I purchased last winter so I will be looking through those and see if I have a better set. Since I was in the garage I decided to go through the allens I have in my kit and put all them in. Now I am waiting for all the new gaskets to come. I leave for work on monday so I know when I get home they will all be here. Its like Christmas every time I come home. I guess it pays to work out of town.

 

[bomber737]

More time in a heated garage and success I got the turn signals wired in and mounted. Took me awhile to go through my stash of signals to find some that are the same as the front. I purchased a set of 4 for this project but unfortunately one of the them had a crack in the stem so now I guess I have 3 of a kind. She would not be happy with that.

And of course when I tried to light them up they didn't light. In all the sets of signals I had of course I had to grab the 2 that didn't have any bulbs. So more cannibalization and they lit up like a champ. And at least I know the flasher works to boot.

Next up will have to be making the headlight work and turn that darn high beam indicator light off. Unless its in high. I am leaving for the next 8 days so hopefully all my stuff will get here and I can wrap up the last of the bars and get the exhaust on the bike. Might even have time to put the carb boots and carbs on. What a hoot that would be.

 

[bomber737]

Finally made it home last night and it was like Christmas. All the parts I have ordered while I was on the road had arrived. I now have all the stuff I need to make huge pregress on the rebuild. I got new gaskets for the engine covers, new throttle, clutch and choke cables. I also finally got the new front brake master cylinder and clutch perch. Soooo shiny. I also broke down and picked up a set of used side covers so those will have to get stripped and repainted when I do the tank.

The side covers even have all the mounting tabs still in place so new gromets are going to be a must purchase. I also picked up a tube of autosol so the exhaust will be the next task tackled. And I need to find some mounting bars since the GL frame and the 1000 exhaust I have mount differetly.

 

[bomber737]

More time tonight to work on the bike. I got the handle bars completed. I got the brake master cylinder mounted and the new throttle cable mounted and routed. I also got the clutch perch and clutch cable mounted but its not routed properly, tomorrow. I finally got the correct choke cable and got that mounted to.

Nice and clean looking I think. Since I put a new master cylinder on the bike I had to make leads for the tail light. A couple of connectors and the taillight works. You would never know I made the leads and this master cylinder has a nice switch built into it so no more messing with the Suzuki spring style switch silliness. I know it's kinda silly but I got a great deal on the master cylinder and clutch perch as a set. Unfortunately they have skulls on the end. So I guess shes going to fit in with the Harley set when we ride out to Sturgis this next summer.

New gaskets got installed and the engine end covers got reinstalled and I think with a little gasoline the Suzuki bond will clean right up and youll never know its there. I put oil in the engine and no leaks so I guess its a nice tight seal.

I had had a problem with the headlight not working and the high beam light on the gauge cluster being on all the time. I figured it out, there are 2 yellow wires by the coils and I had them reversed. The color is so close that I think it must be a typical mistake, but now the headlight works and the high beam light illuminates when it should.

Now I need to get a broken screw out that holds down the starter cover. That should be fun, there is so much space in there. Then I will tackle the exhaust. I am not looking forward to that. I think I might need to see my local welder because one of the mufflers has a small hole on the underside.

 

[bomber737]

I have been waiting for parts to get to my house and they finally arrived so I could get some projects done. I have been waiting for a bunch of LED light bulbs for the gauge cluster to arrive, a bunch of the bulbs were burned out. I will be replacing all the bulbs in my gs1000 as well. Since I will be putting a windshield on the bike I did not want to have to pull it when the 30 year old bulbs burn out at the worst time. So now I wont have to worry about changing them any time soon. I really like the way the cluster lights up now and you can even see when the high beam is on. It finally lights up bright enough to be seen

I also finally got the last of the engine badges and got it mounted. So at least now the engine is complete.

Of course I was on the phone talking with my parents when I put it on so the first time it was installed i mounted it upside down. Im so stupid. So i had to pull it back off and spin it right side up.
Now I am just waiting on the new o-rings for the intake manifolds and I have found a rust spot on the bottom of the left muffler that I will have to get TIG welded so it wont leak. I also ordered a new set of exhaust header inserts so I can get them tightened down when I mount them up. We will see if G&S gets them to me in a timely manner. If not I will never order from them again. I will have to make rear mounts since they are not the same as the 850

 

[bomber737]

Getting closer to the end now. It has been so cold up here in da nort that I have not been doing much on the bike lately. Indoor work mostly and the wait for parts has been a constant pain. I got new boots and clamps for the airbox and got them installed.

I had already cleaned and rebuilt the carbs so it is nice I will finally get to try them out.

They have been waiting for the last year for me to get this bike to this point. They are clean but I did not do any polishing on them so she is just going to have to be happy with them functioning like new, even if they don't look like new. I mounted the carbs to trial fit them on the airbox and they fit perfect.

I really cant wait to hear this bike run for the for the first time. I hope things go with out a hitch. I will be taking the exhaust to the welder tomorrow to get a small hole welded up.

 

[bomber737]

Making more progress now it's not -20 out side. My garage heater can finally keep up, I hate it when I get icicles hanging from my ears, and other parts. I have been trial fitting my exhaust and figuring out what kind of strap I need to make to hold the rear. I finally got the parts I needed for the inner pipes. All I have left to do is clean the right side exhaust and get it polished up tonight. Ill have pictures of it when it's done. I will also be painting the patch on the left side muffler. It's on the bottom so I am just gong to hit it quick with some aluminum colored paint so it won't rust in the future. I did get the new orings for the intakes and got them mounted.

I do still need to figure out what I am going to do about the inside retainer for the starter cover. The bolt sheared and I cant get at it with any of my extractors or drill bits. So I am planning on either putting some high temp RTV on the lip or use the oil pressure bolt and a strap to hold the cover down.

 

[bomber737]

I finally made it home from work the other night, I thought I would never get home and I had to go all the way out to Los Angeles and come back to Atlanta via CanCune. Guess I am still a little ****ed I had to work on two of my days off. So when I got home the other night I went to my Zen place and got the carbs and airbox installed on the GS. I am using a 1000 airbox and the whole thing (carbs and airbox) must be a little longer than the 850 airbox because the airbox mounts are further back. Not really sure why, perhaps I used the wrong airbox to carb boots but it fits in there and its all installed.

Next thing to get done it mount the exhaust and see if she runs. I finally got the muffler hangars I ordered and I have nice new stainless allen screws to go in. Keep your fingers crossed for me and I will have a video on YouTube hopefully.

 

[Good Times]

Good work!

Just a heads up, you MAY have some issues with the fuel filter in the line. typically the gravity fed lines are filterless.

 

[bomber737]

I hear you about the filter but I have run this type of filter on my GS1000E and a couple of GS850's with no adverse affects. I don't like to rely on the pet cock filter to do a good enough job at filtering any crap that might be in the tank. I also modify my pet cock's to have an on-off-reserve function eliminating the vacuum feature. Exhaust is going on tonight so keep your fingers crossed that it fires up and I can be almost at the finish line with this project. Her birthday is coming in march and I want to have it ready to present it to her with a huge bow on it.

 

[Good Times]

I hear you about the filter but I have run this type of filter on my GS1000E and a couple of GS850's with no adverse affects. I don't like to rely on the pet cock filter to do a good enough job at filtering any crap that might be in the tank. I also modify my pet cock's to have an on-off-reserve function eliminating the vacuum feature. Exhaust is going on tonight so keep your fingers crossed that it fires up and I can be almost at the finish line with this project. Her birthday is coming in march and I want to have it ready to present it to her with a huge bow on it.

Cool deal. Good Luck!

 

[bomber737]

Thanks, I am nearing the finish line. I got the exhaust on and all tightened up. So last night I decided to try and fire the bike up. With some cranking to get fuel in the little passages of the carbs it came to life. http://youtu.be/8_X3pDVJd9Q
I hope this link works and if it does sorry for the way the video is displayed.

I think the exhaust came out nice considering it is for a GS1000 and I put it on a GS850 frame. New stainless bolts holding the headers on and a bunch of anti-seize.

There is one thing that I still can't figure out. i have these 2 wires not hooked up and the colors are wrong to go together. Can anyone help me out with this? There are no other wires that dont have a mate and the bike is charging and starting like it should. All the lights and everything else work like they are supposed to so I am kinda at a loss. Of course I don't have a manual for a 850.

 

[eil]

Nice! This cold winter has kept me away from the garage and I don't have the budget for a heater this year, so I have to live vicariously through threads like this until we get out of the freezing temps. (Only another MONTH or so... )

I think this was already answered in your other thread, but if you already have the stator connected directly to the R/R, those just run up into the harness and now do nothing. If you put a multimeter across them, they should measure zero ohms. On my bike, I connected them together for the sake of tidiness, but they can be left hanging if you so prefer.

Of course I don't have a manual for a 850.

BassCliff does! http://www.mtsac.edu/~cliff/storage/gs/GS850_Manual_HiRes.pdf

Practically everything in there applies to the GS1000 engine as well. Here's a good color wiring diagram, if you need it: http://members.dslextreme.com/users/bikecliff/images/80GS850GT_wiring_color-new.png

 

[bomber737]

I did test the stator for resistance before I put the cover back on the engine with the new gasket using the stater papers. It tested good. Now that I have the bike running I will test the voltage output. The bike is charging and I have a micro volt meter so that will get wired into the gauge lights so she can keep an eye on it when she is riding.

It's been so cold here the last month (-20 to -30) that it felt warm at 32 degrees and I was sweating from the heat off the engine. I didn't need a fan to blow cooling air at the engine today. I just left the garage with the door open and let is snow on me when I was syncing the carbs. I am sure the neighbors think I am nuts. It's been snowing here most of the day so I get to use my new snowblower, I can't wait for morning.

I purchased the Morgan carb tune and I put the restrictors in like the directions said but it showed very little on the gauges so I went back to my Mercury sticks and they worked great again. i am just tired of carrying them around when I sync other peoples bikes. We'll see how the Morgan works with out the restrictors in the lines.

Thanks for the links. I printed out the wire diagram and downloaded the 850 manual. Now if I can just find a good set of non emgo rear shocks the suspension will be complete.

 

[bomber737]

Finally got home after 3 weeks on the road. When I left it was 50 and figures now I am home its 20 again. But I got out in the garage anyway. I found that the airbox boots I had installed put the airbox to far back to work for the side covers so I changed them out to a different style. Now the side covers and airbox look like they should and I was able to get the bolts in the airbox mount.

I fired the bike up again and I think I will have to sync the carbs again and make sure its the same as before. It was to cold to start stripping the tank out side so I installed the heated grips and wound up re-routing the throttle cable. It was a little stiff and now it works nice and smooth. All I have left is a little wiring work and see how they work.

I also installed a USB power plug so she will be set up for touring. We are planning a few long trips this summer and its nice to be able to use the phone's GPS but that drains the phone battery so fast. Now we wont have to worry about that.

The new rear shocks finally arrived and I got them installed. Now the only thing left to do is get the front brakes bled and the tank started.

 

[Grimly]

That's coming on nicely.

 

[jsandidge]

shocks

shocks

What are those shocks? Where did you get them? They look great!