1981 GS450E Rebuild

[landshark]

I believe Inox is superior to WD40 if you are going that way Pete (That may just be personal preference tho?)

[pete]

I believe Inox is superior to WD40 if you are going that way Pete (That may just be personal preference tho?)

Hmmm never tried Inox, just always seem to have WD40 handy is the main reason I use it. I'll have to keep an eye out and get some next time I'm somewhere...

[pete]

Grrrr some eBay sellers annoy me! Ordered the HEI modules on Friday and paid Friday evening with Paypal, and they posted them today! I find that a little poor even if they are cheap items... oh well... might get them tomorrow, more likely Friday or Monday, so definitely no startup is gonna happen this weekend.

I did duck down to the garage for a bit tonight and started version 3 of my cardboard exhaust mock up.

Best pic I can get on the bike while holding it as I'm basically leaning on the car bonnet to take it:



And sitting on the bench to give a better idea of how it sits:



So, routing on the left side is a lot easier, doesn't interfere with the dip stick, and I've also managed to get both headers a reasonably even 28 inches which is excellent.

A 24 inch pipe to a muffler gives the target measurements, might get that done tomorrow night depending on the HEI modules.

My only current concern with this layout is still heat related. If I exhaust wrap, that should take care of it generating too much extra heat, but the pipe across the front of the cylinders will block some air flow there.

I wonder if that's too much blockage or if it will be ok? There's also going to be a little blocking on the left side, but not much...

Any thoughts on the air flow anyone?

[jolo]

Hi Pete (not Paul - haha!)
Just finally got caught up on all 68 pages, great thread!
Unfortuanately I'm too much of a noob to have any suggestions, but your bike is looking fantastic.
Definately making me feel motivated to get my 400 in top shape.
Good luck, and I'm looking forward to seeing the end result!

[pete]

Hi Pete (not Paul - haha!)
Just finally got caught up on all 68 pages, great thread!
Unfortuanately I'm too much of a noob to have any suggestions, but your bike is looking fantastic.
Definately making me feel motivated to get my 400 in top shape.
Good luck, and I'm looking forward to seeing the end result!

Cheers Jolo, it is a bit of a marathon read isn't it? Glad you survived it

Thanks for the kudos and you'll do well with your 400 for sure.

[landshark]

Any thoughts on the air flow anyone?

Ride Faster?

[scottychop]

+1 on ride faster. I don't think you'll have any problems as round pipes don't actually "block" flow.

[pete]

Haha cheers guys! Ride faster... now why didn't I think of that?

[hillsy]

Hey Pete,

I know you're committed to making your own ignitor, but this turned up on eBay Oz yesterday:

http://cgi.ebay.com.au/EARLY-SUZUKI-GS250-450-500-80-82-CDI-UNITS-/160556300607?pt=AU_Motorcycle_Parts_Accessories&hash=item2561e6b93f#ht_551wt_907

Just thought you should know

[hillsy]

Oh yeah - my $0.02 on your exhaust.....

I think the curves are going to be too sharp and might impede the flow. Also, you might find your exhaust fabricator will have trouble getting curves that sharp too.

And finally, the exhaust ports angle out - will you be able to bolt the headers on if they are one piece and angled?

Have a look at CL Honda pipes (CL350, CL360) and you'll see how they swoop around to the left a lot smoother.

Like I said, just my 2c - and feel free to ignore it if you've already covered all this

[pete]

Hey Pete,

I know you're committed to making your own ignitor, but this turned up on eBay Oz yesterday:

http://cgi.ebay.com.au/EARLY-SUZUKI-GS250-450-500-80-82-CDI-UNITS-/160556300607?pt=AU_Motorcycle_Parts_Accessories&hash=item2561e6b93f#ht_551wt_907

Just thought you should know

Thanks for the heads up, although I gotta say I'm not real fussed on forking out $100 for something the same age as the one I've got which is busted... but he has two... and a 14 day return policy... hmmm...

I don't think so, but will sleep on it...

And I haven't got my HEI modules yet, surprise surprise.

Oh yeah - my $0.02 on your exhaust.....

I think the curves are going to be too sharp and might impede the flow. Also, you might find your exhaust fabricator will have trouble getting curves that sharp too.

And finally, the exhaust ports angle out - will you be able to bolt the headers on if they are one piece and angled?

Have a look at CL Honda pipes (CL350, CL360) and you'll see how they swoop around to the left a lot smoother.

Like I said, just my 2c - and feel free to ignore it if you've already covered all this

Mate you're on the money and all the "curves" I've done with the cardboard are really bad in terms of being too tight, so I'm definitely expecting the real thing to be a lot smoother and better for flow.

I was never much good at arts and crafts in pre school, so I'm just showing that now I'm, well, alot older... I'm still not much good at arts and crafts

I'm really relying on the exhaust guys to clarify for me what's possible and not possible and will or won't impede exhaust gas flow.

[landshark]

I was never much good at arts and crafts in pre school, so I'm just showing that now I'm, well, alot older... I'm still not much good at arts and crafts

We could have a finger painting party after you have prepped your tank and stuff if you like?

[pete]

And on the dodgy arts and crafts theme... seeing as there's still no HEI modules tonight, I finished off my exhaust mock up, although it's lacking a "muffler" as I'm not sure what shape I'd prefer there. A pea shooter would be nice but may make it too long...

Anyways, here's my dodgy cardboard mock up in all it's... well... glory?





And I also did up a template so I can get some tin or something and make up my new electrics tray:



Hopefully a trip to Bunnings is in order on the weekend so I can pick up a few things like a sheet of tin or similar to make the electrics tray, some thicker sort of metal to attempt to make the bracket for the left carb so I can have a 'bar mounted choke lever, and also look for a small fuel tank and tap so I can use that for the first start.

[pete]

We could have a finger painting party after you have prepped your tank and stuff if you like?

Man that'd be too cool! Get all the South East Qld GSR members together to finger paint my tank... I'm sure that'd be a successful venture...

[tkent02]

I'm just curious why you want the pipe up in the leg burning zone?