1982 GS650g to Cafe

[Bonehead]

I know, not too much of a good start for a cafe bike but its what I have. So, take a seat and enjoy the show. Recently, I've just been doing regular maintenance like oil, brakes, carb cleaning, etc. I am waiting on parts for G&S Suzuki (intake boots, kinda important) and after a few more tweaks I will be ready to fire it up and get going with the project.
Things I have done:

• New brake fluid (out with the old, in with the new)
• Replaced the sludge previously known as oil and the filter
• Full carb rebuild... Twice (actually got a new set since a bunch of the jets were seized/destroyed).
• Spark plug boots replaced, fresh wire>boots.
• Coils re-mounted with new screws, nuts, etc.
• Upgraded to an adjustable Nissin MC from an FZR1000 (OEM MC was mangled)
• Wired in a 650 Katana RH controls (Old one was missing parts/not connecting)

Still left

• Dents, paint, powdercoat, rust, engine paint
• Tires (Going with Shinko 230s, 110 front 130 rear)
• Dynojet Kit
• Dyna green coils
• New seat/fiberglass
• Fix a few wiring faults, then clean up the harness
• Rework electrics, relocating to the tail
• Fine tune carbs
• Valves
• Brake pads front/rear
• Shocks (Hagons, group racing, or RFY depending on money)

Current pictures

NEW MC

Seat, tank, fender mockup

Some mock ups when I was bored and it was raining.
(So what do you guys think? If I go all out, I may paint the frame the same color as is on the tank now or close enough.. Or, may just leave it black. I know the seatpan is wayyyy too long, I just did it to cover up the frame/locking mechanism)

 

[Toast]

Its nice to see another GS project here , I'm looking forward to seeing how it all turns out!

btw I have an extra GS650G tank that's pretty straight if you decide not to bang out the dent.

 

[Bonehead]

Its nice to see another GS project here , I'm looking forward to seeing how it all turns out!

btw I have an extra GS650G tank that's pretty straight if you decide not to bang out the dent.

I knew I wasn't alone!
I'm not going to lie Toast, I have been lurking on your build thread on GSr for quite a while haha. I may take you up on that ;D
Throw some pics and a price either here or GSr. I check GSr much more often then here (my username is the same as this one).

 

[LovingtheCLE]

Another GS650 owner here. I will definitely be keeping an eye on your project! I can't wait to see what you do. I'm just starting to do a few things to my 82. It will be a couple of years before it is finished. In the meantime, I hope to learn as much as I can from guys like you.

 

[Gram]

Subscribed, looking forward to seeing it develop.

 

[gk45011]

Welcome. Nice to see another GS here. Never to many.

GK

 

[Bonehead]

Update: Fixed some of the faulty wiring that was held together by crimps. Also soldered up the W/B wire from the R/R seeing as how I thought that was just a little important. Took out the clutch safety switch loop (now I can remove those wires as well so it will look cleaner). I tried to get the dents off the tank with the HFT dent repair bar to no avail. They are pretty big and quite deep so I understand why. Time to find a small piece of rebar and get the dents out!!

I also realized my clutch cable was extremely tight (it is a damn hard pull, even for me. It requires my whole hand). Took a look at it, and decided to just get a new one seeing as how it should probably be replaced anyways (might still be the original to be honest). So I'll see if that helps. I'm also getting some brake pads as well as a replacement clutch lever if I need to. I will take the clutch lever off and see if I can clean and polish it well enough, wire wheel here I come!

As an added bonus, ;D MY INTAKE BOOTS FINALLY CAME IN! ;D
So happy. I will, finally, be able to put my carbs back on the bike. I will need to get some pods though. I'm leaning towards Ape Super Pro Air Filters (1/3 the price of K&N same build quality I have heard), but may just get those crappy Emgo pods for my "holy shit I just want to hear this thing run" part of the project. But, I hope I will not do that because I need a few other things first!

 

[Jonny_C]

Not sure how I missed this one. I ended up going with the K&N RC-2382 filters. I tried the "XS" ones from MikesXS, but they were total crap. Luckily he only sent 2 out of 4, so I was able to return them for a full refund. I just finished polishing the float bowls and caps last night, so my carbs are all set to go.

Btw, what seat is the one currently on your bike? Surprisingly that might be exactly what I'm looking for for the "brat" look that I want.

 

[Bonehead]

Not sure how I missed this one. I ended up going with the K&N RC-2382 filters. I tried the "XS" ones from MikesXS, but they were total crap. Luckily he only sent 2 out of 4, so I was able to return them for a full refund. I just finished polishing the float bowls and caps last night, so my carbs are all set to go.

Btw, what seat is the one currently on your bike? Surprisingly that might be exactly what I'm looking for for the "brat" look that I want.

I looked at those K&Ns because a knock off set of the exact same model are what came with it. Though I tried putting them back on the carbs (before I even put them back on the cylinder head) and they didn't go on. I measured them and they are a good 10mm smaller than my bells on the carbs so oh well (or maybe i was just not trying hard enough haha). I was going to get them anyways, but now I have to.

With the seat, I have no idea it came with it.. If you want it its yours. Honestly, I have no use for it and don't really even want it on the bike as a temp seat.

 

[gk45011]

Awsome deal. I can't wait for more progress. If he doesn't want that seat i may take it off your junk shelf. Let me know. I am a huge fan of the original Zuk colors. I am excited to see the finished scheme.

GK

 

[Bonehead]

Awsome deal. I can't wait for more progress. If he doesn't want that seat i may take it off your junk shelf. Let me know. I am a huge fan of the original Zuk colors. I am excited to see the finished scheme.

GK

This one was painted after the Wes Cooley 1000s bike. That thing is a beast, but mine is far from a Cooley (for now ).

 

[Bonehead]

;D UPDATE ;D

BRAKES
I was going to just replace the brake pads, but I took a look at the calipers/pads and they had so much crap in the body of the caliper it was disgusting. I have decided to do a full rebuild for all the calipers since I took a look at one of them. Better to do it now, rather than have a troubled time doing it half-assed. Might also go with SS lines, but I may not have enough cash.

WIRING
Put the battery on for a few minutes to check if my killswitch worked. Well, after it didn't I checked voltages at the coils/killswitch and they were 0.00 even when I jumped the solenoid. So, figuring this was a problem I will be tracing the wiring in the harness. I also think that my ignitor may be at fault. But, it was a drained battery going for max 10V across the posts. This is my electrical post in the forum if you want to see what's up

CLUTCH CABLE
Replaced, but feels the same. So, it may just be a hard clutch. Oh well, the cale still looked rusted and old and probably needed to be replaced regardless.

 

[gk45011]

re-check your cable routing. a slight deviation made a huge difference in lever feel on my 450. The Zuks (at least Mine) was very particular when I changed the clutch cable. With a little playing I have a smooth, firm lever and great activation now.

Just saying,

GK

 

[danejurrous]

The clutches on the old Zuks are a little tight, well at least any one I have ridden has been. My 750 had a somewhat tight clutch cable although would still slip when I would grab some throttle and I ended up going with stiffer springs. As long as it is smooth and does not bind up it will be a little tight, you get used to it after a little while.

 

[Bonehead]

SHHEEEEE BREAATTHHHEEEESSSS!!!! This really made my day. I feel so much better about this bike you have no idea. On the very first crank (which I did not record) it scared the crap out of me. I had no idea how strong it would crank over... and it sounded strong to me. Praise be the Suzuki gods and goddesses!

On the other hand, I figured out my RH kill/starter button did not work so I removed it and will be reworking it and see what I did wrong.

This also makes me want to work on it even harder... And spend even more

 

[Bonehead]

So, I made some progress this last week.

1) Got a new seat (an original actually, pretty good condition)
2) Replaced solenoid= RH Kill switch now WORKS PERFECTLY (after chasing electrical gremlins for weeks, I got tired and just replaced it).

Mock up:

 

[Bonehead]

UPDATE

-Got some pods from APE. These things look bitchin.

I must say, they look the exact same quality as K&N to me. Man, I cannot WAIT to hear this monster gurgle into life through that Yoshi pipe and pods... I am so close I can taste it.

Here's a little mockup

 

[JRod294]

I was so glad to see another GS build, I had to register!

I just got mine last week. Hope I can get it going soon. Look forward to seeing your progress!

-Rod

 

[JRod294]

CLUTCH CABLE
Replaced, but feels the same. So, it may just be a hard clutch. Oh well, the cale still looked rusted and old and probably needed to be replaced regardless.

My clutch is super tight as well. It only started moving when it warmed up a bit the other day.....

 

[Bonehead]

My clutch is super tight as well. It only started moving when it warmed up a bit the other day.....

Congrats My build has been a labor of love but slow as hell due to budget. But after my tax refund, I have a hell of a lot of wiggle room.

I replaced my cable, and it feels a lot better. You can also get a cable luber for about $20 from amazon and that should help. But, it may also be that a PO replaced the clutch springs with non-OEM hard sprung ones. But, start with the cable first haha.