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1981 GS450E Rebuild

  • Thread starter Thread starter Guest
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I finished up my temporary starter solenoid bracket tonight which is just to hold the solenoid and ground it for cranking until I get my spark issue and electrics tray sorted.



I did give it a quick flick of the starter switch tonight and it cranked :D

I have yet to get some different oil to put in for the first start (going with Castrol GTX Diesel 15w40) so I didn't give it a proper cranking or anything.

I also went and met up with John today to borrow his scope to analyse the signal generator output, so the ignitor thread has had an update also and I now have a better understanding what's going on there.

My housemate brought the GS650G Katana seat back with him today that I bought from eBay and while the shape of the rear isn't quite what I was expecting, it should be sufficiently longer than the OEM seat to do what I want.





I'll need to cut a bit of the plastic underneath to allow it to sit on the frame rails properly, and I may be able to use the levers that are on there already to secure it.

Even though the cover's in pretty good shape, it has a few tears and things and of course the red won't suit so it will need recovering, but the foam actually feels pretty good.

I'll also need to drill out the rivets for the front tang so I can adapt something there to fit the frame on the 450 but that shouldn't be too hard.

I threw it and the tank on and took some more pic's and I'll do some editing of these at some point to see how it will look if I make an embedded tailight to fill in the rear of the seat and also to bring the seat down to where it will actually sit on the frame rails:

 
Wow Pete, this is th first time I'm seeing this thread (noob to the site). Great work! I'll be watching from here on out.
 
Cheers Rich! I'm very keen to get this spark thing sorted and move on, very frustrating at the moment when I have so much more to do...

I just had a look and realised I missed your first post with the GR's! No idea how I missed that, but I will go take a look now...
 
Nice work Pete, you must be as happy as a dog with a belly full of pee and a street full of lamp poles.
Still trying to get to grips with the exhaust, it will grow on me once the real deal is on I guess.
Keep up the good work.
 
cowboyup3371 said:
Great work Pete. I'm really enjoying your progress.
Click to expand...

Cheers Cowboy, nowhere near as close as you are unfortunately, but it's definitely getting there!

Flyboy said:
Nice work Pete, you must be as happy as a dog with a belly full of pee and a street full of lamp poles.
Still trying to get to grips with the exhaust, it will grow on me once the real deal is on I guess.
Keep up the good work.
Click to expand...

Hahaha I like that... and yeah that's pretty true indeed.

I think the exhaust will end up a little longer with a muffler, and yes it's not quite right in cardboard.

Once I get some image editing done I hope it'll look a little more like I envisage the end product, although I am a little challenged in the editing side of things.
 
After doing some more work on the ignitor issue, I took the 5 minutes to remove some of the seat hardware. Unbolted the latches and drilled out the rivets holding the tang on the front:



I must say that hand drill is coming in very handy. No noise drilling is great at night :)
 
I've neglected to update this thread for a few days, so for those following this that aren't following my ignitor thread, I actually got some spark happening last night.

It's a bit early to say if it's a proper solution or not, but it's definitely heading in the right direction!
 
So... here's the circuit I'm currently using for the ignitor replacement, but I witnessed some ghost sparks tonight so I'm not sure it's quite right yet:



And this arrived in the mail today too:



I used a multimeter to map out all the wiring connections so I can hook it up in place of the old one, so now all I need is to find a choke cable for it and work out how to adapt that to my carb.
 
Pete, I may have missed it, but where are you from?

Edit: I'm blind. You're in Australia. Duh.
 
All good Rich, plenty of times when I'm blind like that too :D

Sometimes there's even alcohol involved...
 
Spark time tonight, looking like I'm on track for the first start attempt on Saturday :dancing:

 
Based on your previous excellent work, I am sure you will have no problems you cannot overcome.

It looks like the cardboard tube idea is working well for you, I can't wait to see it in metal!

Great work so far Pete!
 
Macguyver said:
Based on your previous excellent work, I am sure you will have no problems you cannot overcome.

It looks like the cardboard tube idea is working well for you, I can't wait to see it in metal!

Great work so far Pete!
Click to expand...

Thanks Mac, you just never know. I haven't been able to do much more than turn the engine by hand to test the ignitor replacement yet.

As for the cardboard tube idea, yep it served its purpose well. I have a couple of pic's I'm slowly mocking up with what I want with the new seat etc.

Once I know the engine's good I can call Tranzac and start getting the exhaust organised.
 
pete said:
Spark time tonight, looking like I'm on track for the first start attempt on Saturday :dancing:

Click to expand...

How can you wait that long, fire that baby up!! LOL Seriously though, good luck even though you won't need it :)
 
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