1981 GS450E Rebuild

[landshark]

No worries, i just hope you make it Saturday morning!
Look forward to seeing the beast one day, i should be fully on the road by 10th Jan(thank you Xmas holidays).

 

[Leigh]

I'm a fan of While-U-Wait things.

 

[Guest]

No worries, i just hope you make it Saturday morning!
Look forward to seeing the beast one day, i should be fully on the road by 10th Jan(thank you Xmas holidays).

Me too! The only thing at this stage that could stop me is that I'm on call for work this week... if they call me right when I'm supposed to be at Geebung I won't be happy... and probably neither will the poor person who calls me :-\\\

10th Jan hey? Lucky sod! If I've got the motor back in the frame by 10th Jan I'll be stoked!

I'm hoping a few of us around here and the coast can meet up at some point, would be cool to put some faces to screen names.

I'm a fan of While-U-Wait things.

Oh indeed... I'm all for instant gratification

 

[Joe]

Great thread! I'm about to start stripping down my 650 motor and you're giving me some much needed motivation!

 

[Guest]

Thanks Joe, I'm really itching to get the motor done so I can fire her up and get on with finishing the rebuild.

This is my first ever attempt at something like this, so I'll be extremely happy when it's done and working.

Good luck with your 650!

 

[landshark]

10th Jan hey? Lucky sod! If I've got the motor back in the frame by 10th Jan I'll be stoked!

I am quietly confident that something will go wrong, so dont get too jealous.

 

[Guest]

Haha now I know that feeling well!!! I have no expectation that I can simply get the valves faced and lapped in and all will be good...

 

[Suzuki_Don]

Great thread! I'm about to start stripping down my 650 motor and you're giving me some much needed motivation!

Joe is it an "E" or a "G" model. The motors are different.

 

[Guest]

Did a very small amount tonight, and did a bit of a tidy up on the work bench because I had tools everywhere and they were cramping my style. I really need to finish organising all the tools so they've got a proper home instead of just an area... maybe after the GS is done...

So, valves bagged up ready for travel tomorrow:



Then, moved on to start cleaning up the right hand case cover, tis a tad filthy and greasy and definitely needs some polishing action. Note the gasket stayed about 95% complete when I removed it too, but I have a replacement anyway:



Out came the signal generator, needs a bit of a clean too:



Reference picture for the oil pressure switch connection (haven't removed the switch):



After that, I gave the really greasy bits a good run over with the kero and paint brush and I'm still amazed at how quickly that makes a huge difference. I did pick up a couple of PO issues, a nice gouge and a scratch that I should be able to polish out:



So that's all for tonight, off to get a relatively early one and hope the phone doesn't ring too much so I can get out early in the morning.

I need to duck into the SES and pick up some sand bags for the rumpus door as we got some water coming in during the storm again yesterday, and then I need to go and get the valves faced.

Depending on time, I'm hoping to stop in somewhere and pick up some lapping compound and a hone as well.

 

[Guest]

Well... nearly 2am and I'm sitting here at work twiddling my thumbs waiting for this upgrade to start... an hour behind so far.

So, thought it time to pop in a little update naturally

I have no pic's right now, but I do have good news... yay!

Headed out yesterday morning and picked up some sand bags for the rumpus door and then up to Northside Cylinder Head Specialists... which was closed!

However, I decided to be patient for once in my life and it paid off, the dude rocked up about 15 minutes later and he was just running a little late.

So, he bead blasted and faced my valves for the princely sum of $20 And yeah, he also did the top of the valves too so hopefully they shouldn't be much different spec to what they were.

He also took me into the workshop to show me his blasting cabinet and the facing process which was great. I told him this was all new to me which is why I think he did it. He also offered to do my honing which would be great, except he's closed when I think I will get to it.

He also showed me why you should never run a Ford Falcon on LPG from the factory without getting the head work done to put new valve seats in. A taxi head was there with around 300,000km's on it, and the valves have sunk into the alloy head from the gas and it's non repairable without replacing the seats entirely, and a new engine goes for about $400 now. Just a little side note there...

On the way back home, dropped into my local little auto place and picked up some find lapping compound and a pair of lapping tools.

Then, later on, I ducked out and managed to get a small engine hone. It's the stone type, but hopefully as long as I'm quick and careful, all should be good with it.

So, once I get some time again, I should be right to start getting the valves in the head, then I should be able to get the cylinders honed and pop it together and in the frame

 

[Guest]

I'm an idiot. A true blue, fair dinkum idiot.

My house mate rocked up with an old hammer needing a new handle this morning, so brilliant idea to use this to make up a sort of slide hammer to get that pesky alternator rotor off.

So far so good:



That's actually the swingarm shaft there, possibly not the best use for it, but after banging away for a bit there were no marks on it and the washer we put on there is protecting the hex head quite well.

However, after about 5 or 10 minutes at it, we realised it didn't wanna give, and that hammer head probably hasn't got enough weight in it.

Anyway, I gave it one last big bang in frustration, but let my concentration lapse and managed to catch the meat of my thumb between the hammer head and washer.



Yeah, it hurts. There's a big triangle of thumb that almost got detached, and that's the second lot of bandaging. I bled like a stuck pig and the first bandage was basically squelching so once it seemed to have stemmed the flow my wife put a second one on, and nearly vomited from how it looked. It ain't pretty under there but I'll spare you all the grisly details.

So, zero progress today and I'm not sure how much I'll be able to get done with my thumb like that.

Anyway, backtrack to yesterday to the good stuff.

Left valves faced:



Right valves:



Do I hear you say "oooh pretty"?

And my acquisitions... fine lapping compound, lapping tools, and the hone:



And, lastly, went up to Supercheap (super crap?) today because the house mate saw a good deal on a compressor this morning on his way through seeing as the one he has at his mum's place is missing heaps of bits and pieces.

So, we made a bit of an impulse decision to buy it.

2.5HP 200LPM (not sure what that is in CFM) compressor with 20 metre hose and 4 piece spray gun set for $199. Apparently we saved $228...

Good deal, but naturally it's not the highest quality stuff, but should be good enough to blow out the head to make sure all the blast media is gone and also should be good enough to spray the tank and mudguards down the track.

We'll pick it up tomorrow, although the spray gun pack is on back order and probably won't have that for a couple of weeks, but as long as the compressor's here that's ok for now.

 

[Suzuki_Don]

That's actually the swingarm shaft there, possibly not the best use for it, but after banging away for a bit there were no marks on it and the washer we put on there is protecting the hex head quite well.

Pete, you need to hit the claw part of the hammer head with another hammer. A lump hammer is about the right weight. And it will come off. The taper is probably super glued, sorry I mean Loctited to the shaft. It was with mine and on about the third whach with a lump hammer it came off.

Sorry to hear anout your thumb. Anyway the Aussies gave those Poms a thumping today, 260 odd runs I believe.

 

[Nessism]

Pete,

You need a bottle brush hone. It makes a much nicer pattern on worn cylinders than that straight hone will. 240 - 320 grit is best.

 

[Guest]

Pete, you need to hit the claw part of the hammer head with another hammer. A lump hammer is about the right weight. And it will come off. The taper is probably super glued, sorry I mean Loctited to the shaft. It was with mine and on about the third whach with a lump hammer it came off.

Sorry to hear anout your thumb. Anyway the Aussies gave those Poms a thumping today, 260 odd runs I believe.

Cheers Don, I do recall you using something else to whack yours with. Unfortunately I whacked my thumb first. We have a mini sledge hammer... The only catch could be the free play of the hammer head to the shaft as we didn't realise til afterwards that we should've just drilled a suitable sized hole rather than removing all of the handle

If all else fails, we'll get another cheapo hammer and drill it.

And even though I'm not a cricket fan, it's always good to see us beat the Pom's

Pete,

You need a bottle brush hone. It makes a much nicer pattern on worn cylinders than that straight hone will. 240 - 320 grit is best.

Thanks Ed. I did originally plan to get some sort of ball hone but the price put me off considering I'm going to use it twice only, maybe three times if I ever do the Yamaha YB100 (single cylinder).

How much do you think I'll be causing myself issues by using the stone type compared with the bottle brush type?

I'd love to take it back to the cylinder head guy to get done because he has proper ball hones, but he'll be closed for Christmas/New Year before I get a chance to go back.

On the one hand I want to do the best job I can, on the other hand the only time I can see me getting to do this part is between Christmas and New Year when most of those sorts of places are shut.

 

[landshark]

Hi Pete,
Post a picture of the spray guns when you get them. i have two that i bought cheap, one was too small and not putting out enough spray.
i know there are a million threads on here about paint and equipment, but at least i can tell you if one is the same as my small spray gun and you can avoid it.
PS. move your thumb next time.

 

[Suzuki_Don]

Did a very small amount tonight, and did a bit of a tidy up on the work bench because I had tools everywhere and they were cramping my style. I really need to finish organising all the tools so they've got a proper home instead of just an area...

Hey Pete here's a couple of pics to keep you motivated on doing the tool cleanup that is required at your premises.

Above: My Mostly used tools

Above: MY Less used tools - hacksaws, hammers, etc.


BE INSPIRED PETE.

I know it doesn't look that pretty, just bits of wide board nailed across the shed studs, but it does the job.

Funny thing is once you have a place for each tool you tend to replace that tool after you have used it.

Good Luck.

 

[Woodsy]

ahh you have joined the thumb club! I got my thumb caught between the rear sprocket and the chain when i was adjusting it. Tetanus needle and 30 minutes later i was back on the tools lol

 

[Guest]

Hi Pete,
Post a picture of the spray guns when you get them. i have two that i bought cheap, one was too small and not putting out enough spray.
i know there are a million threads on here about paint and equipment, but at least i can tell you if one is the same as my small spray gun and you can avoid it.
PS. move your thumb next time.

Cool, I'll be sure to post one up when I get them. Housemate picked up the compressor and hose today, so I'll try to get it unpacked and make sure it works tomorrow. Could be interesting minus one thumb but I'll give it a go. We have an air nozzle here already, so as long as it fits the hose it means I can give the head a good blow through to make sure all that blast media is gone.

As for moving the thumb... well... I think that was the problem, managed to give it a good dozen whacks before hitting my thumb

Hey Pete here's a couple of pics to keep you motivated on doing the tool cleanup that is required at your premises.

Above: My Mostly used tools

Above: MY Less used tools - hacksaws, hammers, etc.


BE INSPIRED PETE.

I know it doesn't look that pretty, just bits of wide board nailed across the shed studs, but it does the job.

Funny thing is once you have a place for each tool you tend to replace that tool after you have used it.

Good Luck.

Wow that's nicely organised Don!

We handicapped ourselves by not organising the tools in the garage properly when we bought this house and just sort of tossed everything somewhere.

We have all the stuff to get organised, a peg board for hanging stuff off, a tool box on wheels, another tool box, several of those socket holders you can pop your sockets onto (like you seem to have in your first pic), and other things like an old chest of drawers.

Unfortunately, these days it's either work on the bike or organise the garage, don't get time for both, and I'm letting the bike win out.

Now I am definitely INSPIRED Don!

With any luck we'll get some time to get organised next week as well as hopefully me getting some time back on the bike (pending thumb recovery).

 

[Guest]

ahh you have joined the thumb club! I got my thumb caught between the rear sprocket and the chain when i was adjusting it. Tetanus needle and 30 minutes later i was back on the tools lol

Aaaah I feel your pain! Literally...

I gave it a good soak in Dettol this avo and it looks a little better now that I've cleaned a lot of the blood and grease off...

And yeah, I want back on the tools real soon

 

[Guest]

Ok, I've just done some more searching around regarding hones, and I just don't think it's worth the risk of using the 3 stone hone I got after Ed's advice and looking at other threads.

So, as it turns out I need to work from home tomorrow to get the window tinting replaced on a window we had to get replaced last week, so I think it best I get back onto the good guys at Northside Cylinder Head Specialists so they can do the hone for me.

My only catch will be if I need to clean the lanolin out of the cylinders that the blasting guy put in to keep them from corroding again as I may not have time for that. I also need to find how to preserve it for a week or so until I'll have time to fit them too.

I think this is the sensible and safe way forward though...