GS450S neaten up

[wally]

didn't get half as much done as I had hoped for over the weekend...

got the black GS torn down:


before I got there I took some greaseproof paper, stuck on the relevant panels with painters tape and did a rough trace by hand.



did this to all the decals (only on one side as the other is obviously a mirror image). the next step will be to scan this in and redraw it in illustrator (the joys of being a graphic designer I suppose...). will take some Pantone reference colours tonight for matching, then one of my suppliers will print and apply decals once I have sprayed the tank.

drained the tank and funneled into a jerry can and check what got caught in the sieve!


I think I need a good tank clearing and coating and possibly a carb clean as well!

not sure if I want to go with the std decals or design something which looks like it could have been std??


while the tank is off I need to get a look at where the little oil leak is from, fix it and then try and sort out electrical/charge issue.

if all goes well, it should be back together and running in weeks time or so. let's see...

[Guest]

Nice one Wally, tuning into this... love watching these twins coming back to life

[wally]

OK, so nothing is ever straight forward and simple with older vehicles - you would think I learned my lesson on the Ranchero...

anyway, took off the carbs to give it a clean over the weekend, since i found some gunk in the tank (which will now also have to be cleaned and treated).

seems the left-hand intake boot (is that the name?) has a small crack/tear in it:



is there a way to fix it or is it new parts? if so, do any of the South African guys know if stock is available here or solely off the net?

thanx!

[Guest]

Intake boot is the right phrase

And you can get them from Boulevard Suzuki in the states for about $25 each and it's well worth it. Replace both at the same time as they're probably hard/shrunken as well.

Also, www.cycleorings.com has a combo 450 kit with carb O rings, intake O rings for those boots, and stainless allen heads to replace the philips intake boot screws.

[wally]

thanx Pete! will check it out.

i have some more questions on mind and will post soon for some more input.

[Guest]

thanx Pete! will check it out.

i have some more questions on mind and will post soon for some more input.

Good stuff. If ordering from Boulevard, you'll need to email them a list of what you want so they can send you a shipping quote etc.

[wally]

stripped down the carburetor last night to give it a clean out and boy, what a mess!

also saw that the carb was slightly different to the other GS's one.


Float bowls:


Body:



now I have another problem: main jet's head is stripped in the right hand side - any suggestions in getting it out?

also redrew the tail graphics:


not colour correct yet - will eventually have a full set available as PDF download. also looks like I might be able to get the intake boots available locally!

[Guest]

Eeeew those carbs are ugly... uglier than mine were anyway! A good dip should clean them up nicely though

Bugger on the main jet, is it just the head that's stripped? You won't easily get anything down through the drain hole there to slot it for a flat head screwdriver, so perhaps try a left hand drill bit just a little larger than the orifice? Be gentle and it just might bring it out for you.

An EZ out may work but don't break it off in there...

Also, nice work on the decals!

[Redneck]

No EZ out... ick stay away especailly on the small stuff. Go with the left handed thread bolts. I have snapped two. The first time was my exhaust bolt on the old engine, the second time was the Idle mixture screw on the side of Carb #3.

Paul

[wally]

had a productive weekend.

got wife involved and she helped to get the tank stripped. also got the fender stripped. now they have to be finished up and prepped for paint this coming weekend.







also had the carbs soaking in Clean Green over the weekend and check the residue that stayed behind!!!



bottle on left shows what Clean Green should look like, one on right after it has done it's job on the carbs:



carbs all nice and shiny!



now soaking them in fresh water to get all cleaning stuff rinsed out.

decided to leave the stripped jet in - too much hassle and possible problems.

managed to fix the oil leak - I think! only one of knowing for sure and that is when the bike is up and running again!

i love doing this small stuff - gives me more joy than a massive job done.

[Guest]

Nice work Wally! Wasn't that long ago my tank was as bare as yours... and now it's all painted up nice

[Englishman]

Nice work Wally! Wasn't that long ago my tank was as bare as yours... and now it's all painted up nice

I agree. You have what looks like a near perfect tank there. A nice canvas for your choice of paint.

Mark

[wally]

thanx! is has some minor areas for attention, but all good, straight and dent free!

the cafe racer project bike's tank is another story...looks like the guy took a hit to the nuts on that tank!

anyway, it is going back to black - keeping this one fairly stock.

after this I need to complete my 2 1950s Fridges, then I can get to the Cafe racer project. One fridge has been waiting for almost 2 years now...

[Guest]

thanx! is has some minor areas for attention, but all good, straight and dent free!

the cafe racer project bike's tank is another story...looks like the guy took a hit to the nuts on that tank!

anyway, it is going back to black - keeping this one fairly stock.

after this I need to complete my 2 1950s Fridges, then I can get to the Cafe racer project. One fridge has been waiting for almost 2 years now...

Never fear... my 450 went off the road at the beginning of 2002... only made it back on the road at the end of last year...

[wally]

spent most of Saturday morning sanding and prepping the various pieces:


got the first coat or 2 of primer on before various other duties popped up:



got some small problem areas that'll need some sanding again and hopefully another coat this coming Saturday. Then it will have to wait till next month for paint - bit tight this month with all the birthdays, anniversaries, holiday, etc...

also got the carb back together, bagged and tagged until it is ready to be installed again.