1983 suzuki gr650x - first build attempt

[ToastyTofu]

she's my baby. ;D

move day:

got her for $300. bill of sale reads 3600 original miles. she doesn't run, and most of the wiring harness is missing. also came with a replacement starter to replace the broken one.

she's missing: starter cover bolts, starter bolts, gas tank bolts, tach/speedo assembly/handlebars, handlebar mounting bracket and bolts, headlight bolts, and the battery is dead.

i just ordered a replacement harness.

future plans: new air filter, new exausts, dual disk (if a comparable front end can be found), new seat (and maybe tank), new bars, led tail light, etc. etc.

i've obviously never done this before . i need any and all advice. at this point, all i need is to get her up and running; and i have all the time in the world and 2 part time jobs.

questions:
1. where in gods name do i find replacement bolts?
2. i'm really low on tools. does anyone carry a comprehensive motorcycle toolkit?
3. replacement parts? hell, i can't even find oil filters...
4. is an engine rebuild necessary?
5. does there exist a comprehensive motorcycle modification/restoration guide?
5. clubman or clipon bars?

 

[Deviant1]

Okay let's see...
1.) Go to a suzuki dealership and speak with the person at the parts desk. They'll be able to pull up diagrams of your bike on their computer and the part numbers for the bolts you need. If suzuki still makes the bolts you can order them. Or if they don't the person at the desk will give you the size pitch etc. for the bolts so that you can order them through a fastener company like Fastenall.
2.) You're better off just buying a set of metric wrenches and sockets. Then various sets of pliers and screwdrivers. Buy the rest as you need it.
3.) Again the suzuki dealership may have some stuff. Ebay is a good source for parts as well and they can be had way cheaper than at a dealership.
4.)When you get your harness back together and your starter installed you'll find out if you need a rebuild. A good way to make sure the motor is not locked up is to shift the bike into high gear and give it a mighty push with clutch engaged. Disengage the clutch once you've got some momentum and you should get the motor to roll over. If not you'll need to tear it down.
5.) Clymer makes one for your bike. You can give ebay a shot for one of those. There are other companies that make them as well. There may even be one you can download in the manuals section here.
6.)Clipons hands down!
Good luck dude. I'll be watching this one.

 

[ToastyTofu]

wow... thanks, that was really helpful

 

[crazypj]

You can probably adapt some GS500 parts.
motor traces heritage to 1977 GS400 twin

 

[Big R]

With 3600 miles, the motor SHOULD be ok. But you won't know for sure until the wiring harness is all buttoned up. I remember reading before that the front end from a GS twin with dual discs bolts right up.

Give me a couple hours..... I have the original Suzuki service manual in PDF format.

Great deal on the bike BTW!


Edit: the vast majority of bolts around the bike are the same size - should be able to find them at any hardware store. Same as the tools - pretty normal stuff that you can get easily EXCEPT for the allen wrench used to pull the swingarm pivot/axle thing. It needs a 14mm allen wrench, but let me know if you need one - I can get an extra.

 

[Big R]

Couple hours my butt......

http://rapidshare.com/files/346703802/GR_650_tempter_Service_manual__eng__1983-1984.pdf.html[/url]

Let me know if you need anything else!

 

[hillsy]

Get it running first before you dive in and spend $$$$ on front end swaps etc. Would be a shame to find out your motor is shot after you buy a shedful of parts....

BTW - your front forks look bent is some of those photos ???

Good luck with it

 

[ToastyTofu]

bent?! oh noes!
i'll have more photos up first thing tomorrow.

missing hardware: i'll check hardware stores. thanks for the pdf; i recently aquired a hardcopy...
sorry about that :'(

but yeah. wirin's almost done!!! all i need is to get a battery and some gasoline... fingers crossed.

 

[ToastyTofu]

don't think they're bent... could be though.

anyone got any ideas on the cowl? i want to work with what's already back there stock, if possible. i mean, i can kinda already see it, plus the battery box fits under it and it already has a place for the tailight to go. i also need space to put electronics. the only problem being the slight diviot in the frame...

p.s. i've seen cutting boards used for housing electronics on... personally, i think they're a bit too thick . anything a little thinner and also plastic?

im still waitin' for the battery to come in and some bolts for the starter...

 

[Big R]

The seat cowl? I've seen the factory passenger handrail used - just shorten the front of it, slide it forward on the frame rails, and use that as the frame work for a fiberglass bumpstop.

Could also check out roccitycafe.com and glass from the past if you don't feel like making your own.

Instead of using boards to house the electronics, you could try thin sheets of aluminum. A lot of places that do road construction have old street signs......

Edit: Toasty, I forgot to add - if there are any non-essential parts you need, let me know. Like the fenders, controls, etc.. I have a parts bike but am keeping the motor, carbs, wiring, swingarm, etc.

 

[hillsy]

Best way to check if your forks are bent is as follows:

*Jack up the front of the bike (blocks / jack under motor)

*Take off front wheel

*Loosen forks at triple trees just enough so you can turn the uppers

*Now holding the fork bottom still, turn the upper fork.

If they are bent the fork bottom (at the axle) will move about.