1981 GS450E Rebuild

[pete]

Just ordered the Acewell, so as long as they're in stock at the dealer I should have it later this week and can start working out how to mount it and wire it in.

My only confusion right now is how to make the single indicator light on the existing setup work with the left/right indicator lights on the Acewell. I'm sure it won't be too hard once I get it sorted...

Oh, and mounting the sensor on the front fork/caliper should be interesting also, not much room down there...

[pete]

And on another note altogether, I got department of finance approval today to get an Acewell gauge, which should mean no more bouncy needles and non-working tacho at last!

I hope to order that tomorrow and hopefully the tacho drive blank of plate from the 1100S will fit and I'll try to pick that up locally from the dealer near work too.

Oh, and I started doing some planning for my enhanced battery box and got a diagram with some rough measurements up on the white board.



(A) will bolt to the rear two bolts holding the battery box in and two hinges will get rivetted on the top.

(B) will be the lid and I'll stick some rubber underneath so if worst comes to worst and it did happen to touch the + terminal, it will touch rubber instead of aluminium. The lock will mount at the front (sketched in green) and engage with (C).

(C) is a bracket that will bolt to the front battery box mounting bolt, and will have two parts at the top; one to let the lid rest on and prevent it touching the top of the battery, and a second one a bit lower down which is where the lock will engage.

All will be made out of the 2.5mm alu. I have sitting around to give it some strength and to start with I'll go for the brushed look again. If it stands out too much I'll have to paint it black.

Alternatively, I can get a bit of the 1mm alu. and replace the black plastic side piece so it all looks the same.

I also had a different thought again today... oval number plates instead of side covers, although the left one would have to go under the pipe for practicality which could make it all look a little odd...

[pete]

Looking good Pete. Have you had the metal polish out? I don't remember the engine cases having that mirror finish before - especially on the clutch side. The fly screen was a real touch of quality DIY too.

Mark

Hey Mark, yep, spit and polish yesterday... they're not quite mirror polish though, they just look that way because there was actually some blue sky and sun for the photos They do scrub up well though...

Cheers for the compliment too, very happy with how the screen turned out and keen to get some more km's on her now and see if that gets a little turbulence off my chest up around the 100kph mark.

Looking good Pete. Have you had the metal polish out? I don't remember the engine cases having that mirror finish before - especially on the clutch side. The fly screen was a real touch of quality DIY too.

Mark

[pete]

Pete,

The little screen is looking great! Also your right about the front mudguard riser. In the sun it doesn't look so out of place at all.

Also whats that orange rectangle thing hanging by your chain guard?? Registration of something?

Thanks Tim! Very happy with it

I think that's the big downside with all my pic's being taken in the garage late at night, the flash really doesn't give a true representation of how things look, so it was really good to be able to get some natural light photos yesterday.

Yep, that's my rego sticker... ugly but I gotta have it...

Yea, I was going to say the same, your inspection sticker just looks out of place down there. Is that where it's supposed to be or can it go someplace else, say under your flyscreen?

Scott it's gotta be on the left or rear and easily visible, so that's really the only place I can put it to keep it visible and try not to spoil the lines too much... you'd think a number plate would be enough given that's all the police or transport department use as a reference anyway...

[cowboyup3371]

Yea, I was going to say the same, your inspection sticker just looks out of place down there. Is that where it's supposed to be or can it go someplace else, say under your flyscreen?

Pete,

The little screen is looking great! Also your right about the front mudguard riser. In the sun it doesn't look so out of place at all.

Also whats that orange rectangle thing hanging by your chain guard?? Registration of something?

[pete]

Ok, sussed out the tacho situation today and it's a little odd, but I think it comes down to the fact that I should've ordered the other cable instead of the one I got... maybe... there's two on the fiche and the one I ordered doesn't have the rubber cover on it that my original one did, but I'm wondering now if the bits that engage with the tacho drive and tacho are a bit shorter or something.

I found the cable at the engine side was only finger tight, so thought that might be the issue, but tightening down didn't fix it and the square drive for the tacho wasn't spinning.

Pulled the cable off, cable not broken.

Started her up and the tacho drive is spinning away happily, so the drive isn't broken.

Put the cable back on and tightened down, not spinning, gave it a push and it started spinning. Plugged into the tacho, no go.

I reckon for some reason it's not engaging properly which is just weird... oh well, roll on the Acewell! Fingers crossed for next pay day.

Anyway, aside from that, I got a spit and polish done today and the fly screen mounted up. Took her for a short run to get the chain warmed up for a lube and stopped on the way for some pic's:













Fastest I could get to was 70kph so a bit hard to tell if the fly screen does anything useful, but it held together and didn't rattle or anything annoying like that which is always a good start.

[pete]

Pete,
Your bike looks great man! If it works for you leave it as it is and ride!

Just a quick question I need to order something from Boulevard Suzuki and I cannot seem to get it sorted and they are not replying to my mails.

I seem to recall that somewhere in these thousands of posts you mentioned how it works when ordering internationally from them.

Much appreciated.

Thanks Andre! I'm still stoked that she's done and I can ride her every day

These last little details are annoying me and I want to knock them over but that's it... after they're done she's done and I can move on

Matchless,
They have been very slow lately, there is a thread on here about it. Something to do with new products?
I ordered some parts a couple of weeks ago and it was a slow process, but they came through, and cheaper than the others.
Someone recommended a PM to Ashley here on the forum, just do a search on Boulevard and you should find it.

Yes, definitely been a bit slow of late. I think they're only a small shop and Ashley is the key parts person. I suggested to someone having delays to PM Ashley on here (that's her screen name) and apparently they got an almost instant response to their PM. Might help...

The windscreen looks brilliant mate. Put it on now!!

I'm not so sold on the side covers though. They don't flow with the bike at all, especially unpainted. I noticed you still have the flanges and gromits to house the OEM side cover. One option may be to fit these on (after they've been painted to match of course!!)

However, I think it would be pretty easy to cannibalize some hinges, and a little key lock, and just create either a solid hinge top, or even a pair of some metal straps to lock the battery in. You could attach some of your rubber to the bottom of the straps to protect the battery. Simple, and visually sparse, but providing good security for your battery.

I also agree with Spyug about the fender mounts.... I didn't want to say anything earlier because I thought you'd address it in time. However I think you ought paint your fender extensions black or maroon. The eye does draw right to them

Thanks Tim! Gotta bath her today and check the tacho out, and once I've done that that screen is going on

And I agree with the side covers, the way you said that nailed it for me, they're just not right. Perhaps in black as the other guys said may help them blend in but I still don't think it's right, and I think I'll stick with my plan B of a cover for the battery box, and a hinge along the lines of what you suggested is what's in my mind for that.

I'll endeavour to get some more photos once I've bathed her today out in the beautiful bright blue sky we have for a change (hope it hangs around) and you can see what you think of the front guard mounts then... I still say it's the flash in the garage that highlights them in those photos

Thanks, must have just searched before that was posted. Will watch that thread now and see if there is any response.
It quite amazing how a lapse in service can spread so quickly around the world these days. Its a pity they do not make contact available with their marketing manager on their site.

Yes indeed Andre, it can be very frustrating and I think they should fix that issue as that's the sort of thing that can hurt a business, especially if word of mouth says they're no good.

Matchless,
They have been very slow lately, there is a thread on here about it. Something to do with new products?
I ordered some parts a couple of weeks ago and it was a slow process, but they came through, and cheaper than the others.
Someone recommended a PM to Ashley here on the forum, just do a search on Boulevard and you should find it.

Thanks, must have just searched before that was posted. Will watch that thread now and see if there is any response.
It quite amazing how a lapse in service can spread so quickly around the world these days. Its a pity they do not make contact available with their marketing manager on their site.

The windscreen looks brilliant mate. Put it on now!!

I'm not so sold on the side covers though. They don't flow with the bike at all, especially unpainted. I noticed you still have the flanges and gromits to house the OEM side cover. One option may be to fit these on (after they've been painted to match of course!!)

However, I think it would be pretty easy to cannibalize some hinges, and a little key lock, and just create either a solid hinge top, or even a pair of some metal straps to lock the battery in. You could attach some of your rubber to the bottom of the straps to protect the battery. Simple, and visually sparse, but providing good security for your battery.

I also agree with Spyug about the fender mounts.... I didn't want to say anything earlier because I thought you'd address it in time. However I think you ought paint your fender extensions black or maroon. The eye does draw right to them

Matchless,
They have been very slow lately, there is a thread on here about it. Something to do with new products?
I ordered some parts a couple of weeks ago and it was a slow process, but they came through, and cheaper than the others.
Someone recommended a PM to Ashley here on the forum, just do a search on Boulevard and you should find it.

Pete,
Your bike looks great man! If it works for you leave it as it is and ride!

Just a quick question I need to order something from Boulevard Suzuki and I cannot seem to get it sorted and they are not replying to my mails.

I seem to recall that somewhere in these thousands of posts you mentioned how it works when ordering internationally from them.

Much appreciated.

[pete]

I like the look you did with this but I think it'll be even better if you can paint it to match the bike.

Hmmm... painting hadn't even entered my mind... I need a quick turnaround though so I'm not sure if I'll get time to get it done...

Pete the fly screen looks great. The side covers I'd have to see in person. The exposed bolts and such detract from the covers. To bad it can't be hidden some how.

cg

Cheers Charlie, I'm still surprised that the fly screen looks as good as it does, just hope it's at least as functional as it looks.

I agree on the exposed bolts, that's my main issue with the side covers. If I could weld aluminium that would change things, and I think this is once instance where I wouldn't like to trust JB Weld either.

www.alumiweld.com would be an option, but again it will take a few weeks to get the rods... an option though.

Pete,
The lock looks fine but I am curious as to how many Foster's you had before you mounted your front fender? And since you are the 450 Guru, I have a question. Have you ever run across a remote oil filter conversion kit? I'm not lazy but at my age I don't have as much time as you guys. And from my many years of experience, I learned that those things that are the easiest to maintain get the most maintenance.
Niels

Thanks Niels... what's up with the front guard? No Aussie in their right mind drinks Fosters either

Haven't seen a remote filter conversion at all actually, but then again I haven't looked either. I'm sure a lot of our GS' share the same oil filter setup though, so if something's available for a 4 cylinder, it might be able to be retro-fitted to the 450...

Pete, I'm with Cowboy. I think the side panels need to be painted, otherwise they will be fine. I notice also that the struts attaching the front fender are unpainted as well and, too me, it draws the eye right in. Perhaps they should be painted too, maybe black even.

Excellent work on the flyscreen, we IT Geeks are creative at times aren't we .

Now I take it your office is in a bad part of town and batteries get lifted all the time? Any fear of outright theft or vandalism?

Since you are almost done with her what's the next project going to be?

Let us know how the screen and side covers work out.

Cheers,
Spyug

Thanks Spyug, number two for paint... hmmmm... The front guard mount/fork brace is basically brushed aluminium, and those photos with it in the garage make it artificially visible by the camera flash. I think it fits in when it's in natural light personally...

And yes, we can get creative indeed Very happy with the screen!

The area the office is in is not the greatest, and we've had a homeless guy bashed to death outside the building as well as a number of other things over the years. It's better than it used to be and I'm probably paranoid but having that battery exposed I feel is probably just too tempting for some types, so figured I'd be best safe than sorry...

The next mini project after the screen and covers or battery box will hopefully be a rear carry rack modelled on the stock sports rack which is made out of unobtanium, but the next real project will be the Ducati Cucciolo engine sitting here.

My cunning plan that may be not so cunning is to get my wife to agree to a dual car port out the front which will free up one side of the garage (her Peugeot will have to stay in).

Once that room is available, I'm hoping the Ducati can fund the next bike... hopefully a 750 popup Katana...

I have to agree with Cowboy (imagine that the Redneck and Cowboy agree) okay and the Canook...lol. Painted primary black for sure then maybe some kind of red accent or something like a 1-2" band of black round the outside and red in the middle to match your paint then go get the 450 side cover badges and mount them on the cover.

I like Spy am wondering what you will be working on next or has the significant other banned you from over obsessive projects.

Paul

Number 3 for paint! Thanks Paul... common theme here...

If I do go paint Paul, it definitely won't be anything fancy like that as I'm struggling to think of how I'll get time to even do plain black...

See above for the next project too

Thanks heaps for the feedback guys, I'm going to give this some more thought, but I might end up in a completely different direction yet... I'm still entertaining just enclosing the battery box as is...

I think though if I was to continue with the sidecovers that I would need to start from scratch so they don't have bolt holes, and get some attachment points welded on instead, and I think if painting is the answer they'd just have to be a semi-gloss black to fit in with the rest of the bike...

I have to agree with Cowboy (imagine that the Redneck and Cowboy agree) okay and the Canook...lol. Painted primary black for sure then maybe some kind of red accent or something like a 1-2" band of black round the outside and red in the middle to match your paint then go get the 450 side cover badges and mount them on the cover.

I like Spy am wondering what you will be working on next or has the significant other banned you from over obsessive projects.

Paul