'81 GS850G Cafe project from Pittsburgh PA

[cafeCreature]

Hey guys,

Picked up an '81 Suzuki GS850 for my first bike build. Looking to go the cafe route. Since bringing it home I have removed the fairing and bags, installed dynojet stage 3 jet kit and K&K filters, and transplanted the turn signals and tach cable from the included parts bike. More changes will come as the bank account allows it.

Bikes that I have been looking at for ideas include the following:
http://thebikeshed.cc/2013/05/24/tarmac-custom-mc-gs850/
http://www.dotheton.com/forum/index.php?topic=61418.0
http://www.dotheton.com/forum/index.php?topic=55553.0

Really looking forward to this project and getting feedback and advise you all.

Thanks

 

[spotty]

looking better already, clip ons and rearsets next on the list ?

i've had three of them over the years and the best advice i can offer is - don't change down from 5th to 3rd at anything like top speed.........on a totally unrelated topic the supposedly unbreakable gearboxes in 850G's are not as unbreakable as people might have you believe..........

 

[cafeCreature]

Plans are to re-install the headlight, replace the turn signals with leds, find/make a cafe seat, mount that, probably going with clubman bars and rearsets.

I read HerrDeacon's write up on his seat build and am very impressed. Got me thinking it's almost easy haha.
http://www.dotheton.com/forum/index.php?topic=3374.90

Long term I'd like to find a way to relocate the electronics to empty out that space behind where the side covers would be. Has anyone documented that process yet? My thoughts were behind the solo seat above the wheel but I dont have the specifics figured out.

 

[cafeCreature]

The beginning of my custom fiberglass seat. 3M adhesive and floral dry foam. I will likely shorten it to the same length as the frame. Final adjustments and sanding tomorrow. Then comes the fiberglass. Updates to come as I progress.

 

[98kellrs]

Take this with a pinch of salt if you will, but that hump looks huge compared to the tank?

 

[alzcbz]

I know this isn't your final shape, but try to mimic the size and shape of the rear of the tank. And you may want to shorten it up a bit.
Great start.

 

[cafeCreature]

Thanks guys. Youre both very right. I do have quite a bit of shaping left to go. Admittedly I got a little excited the curve came out the way I had hoped and it didn't fall apart all together haha.

 

[cafeCreature]

Ok, so take two on the seat shaping. Let me know what you think.

 

[Big R]

Have you considered using the rear of the gas tank as a mold for the seat hump?

And round about are ya from? I'm up around New Castle.

 

[cafeCreature]

alzcbz made a similar suggestion earlier. if this mold doesnt work out, Ill likely give it a try.

 

[cafeCreature]

So my latest order from DCC came in today but I'm having all kinds of trouble.
This is what I got:
http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-customer-motorcycle-lighting-parts-7-inch-gloss-black-british-headlight-bucket-66-65068-gbpc.html
http://www.dimecitycycles.com/7-8-inch-raw-dcc-original-speed-clubman-handlebars.html

I cant seem to figure out how to install the sealed headlight to the rim and the bars hit the nut on top of the forks.
Any suggestions?

Im likely going to return the bars and get these:
http://www.dimecitycycles.com/7-8-inch-chrome-clubman-handlebars.html

 

[Big R]

The bars are hitting the nut on top of the forks, and not the triple tree, correct? If so, you can loosen the triple tree clamps and spin the upper fork tube. That might angle the nut away from the bars.

 

[cafeCreature]

That's a pretty good idea. I still don't think I can use these bars though because they wont let me turn the whole way. With a tank this big, I may have to go with a different style bar.

 

[shadowfocus603]

I have the same bike as you. And it was even the same awful color when I got it.
Before:

I've put pods, dynojet kit, and a jardine exhaust, superbike bars, bar end mirrors, and did some painting and here's where it sits now:

The 850G is a great bike with tons of power but you'll find the shaft to be a limiting factor when it comes to high spirit riding. Make sure you have changed the secondary oil as well as the rear gear oil and grease the input splines on the driveshaft where it goes into the pumpkin. Also, for your issue of the bars hitting the fork caps, look for a pair of fork caps from an 82 or later 850. Same diameter fork without the air valve on top. Conversely, you can just unscrew that cap that is hitting the bars. It is just a cover for the schraeder valve for pressurizing the forks. I just went with straight rate fork springs from sonic and am running 15w fork oil with 0 pressure.

 

[cafeCreature]

Thank you for all the advice. I like what you have done with your bike. Do you have more pictures of the exhaust and any info about where you got it?

 

[shadowfocus603]

http://www.ebay.com/itm/NOS-Jardine-Exhaust-Muffler-System-Suzuki-GS750-Thru-1979-GS850-Thru-1981-3800BL-/190580834304?pt=Motorcycles_Parts_Accessories&hash=item2c5f80c000&vxp=mtr
That's where I got mine. It sounds great. Throaty without being buzzy or annoying. I imagine if I popped the single rivet holding the baffle in it would sound better (to me at least, the neighbors not so much ).
View of other side:

Random close ups:

If you haven't already, make sure to hit up the GS resources forum:
http://www.thegsresources.com/_forum/index.php
Most importantly this site is the absolute holy grail of GS info:
http://members.dslextreme.com/users/bikecliff/
Any time you ask a question on the GSResources they will first recommend BassCliff's site as it has tutorials for everything under the sun as far as these bikes are concerned. Another upgrade I recommend when funds allow is swapping to a SH-775 regulator as well as a stator from Electrosport.
Regulator:
http://roadstercycle.com/
You want the super series kit SH775
Stator:
http://www.ebay.com/itm/Electrosport-Industries-Stator-ESG014-/311105577628?hash=item486f56629c&vxp=mtr
The charging systems on our bikes are weak at best and if you plan to go led turn signals etc you will want the new regulator or else you will fry the stator. Also be sure to get the regulator first or the Electrosport stator will cook the factory regulator. The new stator is rated for something like 20% more output than factory so it needs the series regulator to keep everything happy.

 

[sav0r]

I'm in just because Pittsburgh.

 

[cafeCreature]

New bars, grips, mirrors(not in picture), turn signals and headlight bucket. Seat is not yet painted(obviously) or mounted. Still trying to figure out how to mount it.

Been thinking about rearsets. I havnt found any elegant solutions so far. From what I understand, the GS850 frame is nearly the same as the GS1000. FastFromThePast does sell rearsets for GS1000s. Does anyone know if they would work?

 

[cafeCreature]

I dont know if anyone is still watching this but here is the latest on my progress.

Turn signals, tail light, licence plate bracket and lights all wired up and the wires tucked. Only need a seat pad and its good to go.

 

[spotty]

getting there. did you find out if the GS1000 rearsets work?