Tag Archives: GS650

Scraping, Welding, and swearing 

Once we went to change the oil on Katie’s GS650, we realized someone had stripped the drain plug pretty good, and attempted to cure this issue by covering the drain plug with RTV and Teflon tape!

Rather than trying to just bandaid a bandaid, we opted to install a new Oil Pan and OEM gasket. 

In order to get to the oil pan on this bike, the exhaust must be removed in order to gain access. 

As Katie and I were removing the bolts from the manifold to cylinder head, one of the bolt heads snapped clean off 😥, a new experience for Katie.

With the exhaust out of the way, we removed all of the bolts for the oil pan. We tried to remove the pan, but the 30+ year old gasket said no! After some tapping with a rubber mallet the thing popped off. Leaving behind a very stuck gasket. 

Katie was a trooper, and spent few days slowly chipping off the old gasket. But while she was out of town I decided to surprise her to a reassembled motorbike. 

After using a nifty precision scrapper, some oil soaked​ sandpaper, a microfiber with some brake clean, I got the block looking like new! So then I threw the oil pan back on!

That damn broken bolt, turned out to be not too bad. Rather than using channellocks and vice grips, I found a little bolt that threaded over the stuck portion. Originally I tried using two nuts to try and back the stud out, but with no success. 

So I sanded down the nut and the top of the broken bolt and thread a weld on it. Threw a socket and long ratchet on it. Then smacked it with my trusty rubber mallet. Success!

Now the GS is back together again! 

1982 Suzuki GS650

The latest addition to the family! This gem of an 80’s Japanese bike. A 1982 Suzuki GS650-G. Cool like 4-Cylinder SOHC 650cc shaft driven motorcycle, putting out around 70hp (back in the 80’s at least!)

Bone stock, black paint with gold pin stripping, and 48,000 miles on the odometer. The bike runs really well for having a few miles on it. I’d much rather see an older bike like this with relatively higher miles, than too little. Bikes tend to deteriorate if you let them sit for too long.

My girlfriend picked this thing up for a pretty good deal. The previous owner loved the bike, but you could tell he was one of those guys who was a little afraid of working on it, and goofed up a couple of small things.

Some of the initial things that needed to be fixed:

  • Old Battery
  • Idle speed needs to be dialed in, maybe some pilot jetting too.
  • Oil Drain Plug is being held in with thread tape and RTV
  • Clutch Cable is shot, half the cable’s lining is pulled out.
  • Clutch Lever Pivot Bolt is rounded out.

Overall, I love the bike, and can’t wait to dig into it!