1981 GS450E Rebuild

[Guest]

Got home to another present today...



Opened up and I got my 'bars and sprocket...





Tell you what, those new shiny 'bars are feather light compared to the stock chrome ones, I can't believe the weight difference!

So just need to get some loctite and anti seize on the weekend and I'm ready to rock...

 

[Guest]

Nothing hugely exciting this weekend as expected, but I did get out and got some necessary stuff from Supercheap (Bunnings is useless)...

Threadlocker (supposed to be identical to blue Loctite):



Anti seize (no idea how it compares with Loctite but spec's say it's good):



And a nice big syringe to make getting the fork oil in a breeze:



So, if all goes to plan, I should be able to do a lot of reassembly of the frame next weekend, although I still need to give a nice new shiny coat of black to the dress bit over the bottom triple clamp and the chain guard.

At least I'll be able to get the forks and wheels on properly this way, just may not be able to get the top triple clamp on fully as I expect I will need to wait a few days before being able to put the dress bit on top of the bottom triple clamp.

This is the bit I'm referring to (no idea what it's really called), and I want to ditch the fake plastic chrome on it:

 

[Guest]

Some more progress at last yesterday, although it doesn't look like much...

I lost about an hour and a half so I didn't get to paint the couple of plastic bits I wanted to, but I did at least get them cleaned and sanded:



I finished reassembling my forks correctly and they now have fork oil in thanks to my new big syringe, got my front disc torqued up correctly, and same for the shiny new rear sprocket. Everything back together again with the top triple clamp on but not torqued up, same for the new 'bars.





My only grief now is how to torque up the steering head clamp nut as I don't have anything remotely close to what would be needed to attach it to the torque wrench. I'll have a look for a tool when I get some time...

 

[Ricko19]

lookin good Pete

 

[ratdude]

X2 , lookin good

Rat

 

[Guest]

Cheers guys, I'm real happy with how it's going, but it's just not going fast enough

 

[Macguyver]

Looking good Pete.
Rolling chassis are a great milestone on a rebuild. Perfect time to crack a bevy and plan the next steps.

Keep up the great work Pete!

 

[Guest]

Cheers Mac, several bevy's were cracked indeed

I really need to get the engine paint finished though, really really hanging out to get the motor back together and finish it all off... I need to ride!

 

[scottychop]

Favor

Favor

Hey Pete,
Project is looking great. Wish mine was nice and shiny too......! Wondering if you could do me a favor. I am missing my rear motor mount plate (right side). Would it be possible for you to measure the mounting holes Center to center so I can make one? part number 41910-44000-019 is discontinued.... PM is ok too.

 

[Guest]

Sure can Scott, how urgent is it? Right hand side's a little difficult to get to without bringing it all out, so I probably won't get to it until next Saturday when I'm working on it again if that's ok. I have all the mounting brackets loosely attached where they belong.

If you need it sooner I can probably organise something.

 

[scottychop]

Naw man,

Naw man,

take your time. Thanks!

 

[Guest]

Ok, more progess yesterday.

First off, got your measurements Scott. This should be the right bracket:



I traced it to get the measurements down right:



A = 37mm (centre to centre)
B = 30mm (centre to centre)
C = 31mm (centre to centre)
D = 7mm (this is the double thickness where it bolts to the frame)
E = 4mm (main bit of the mount)
F = 3mm (the extra bit like D)

Hope that helps...

 

[Guest]

Something I missed showing last time was that I got the brake actuator all hooked up for the rear drum:



Then I got set for a little temporary spray booth to do the chain guard and dress bit for the forks. I moved it out of the sun to spray too:



And got them sprayed with the Plasti Kote plastic paint:

 

[Guest]

Got the bottom crankcase, valve cover, and sump cover prepared for the touch up coat after my bad prep work last time:



And got the first coat done:



I also gave the starter cover some polishing work but it needs a lot more. No pic's though as the battery was flat by then.

I also polished up the brake lever and put the foot pegs back on.

This is where it sits now:



I'm hoping to do the second coat on the motor parts today and the plastic paint should be cured also (supposedly 24 hours) so I might be able to put them on today also.

 

[scottychop]

Ok, more progess yesterday.


A = 37mm (centre to centre)
B = 30mm (centre to centre)
C = 31mm (centre to centre)
D = 7mm (this is the double thickness where it bolts to the frame)
E = 4mm (main bit of the mount)
F = 3mm (the extra bit like D)

Hope that helps...

Thanks Pete!

 

[Guest]

No probs at all Scott, happy to help.

I did get the second touch up coat on the motor bits today and also got time to loosely put the chain guard on and get the fork dress bit on also. Looks so much better black instead of having those fake plastic chrome strips on it!



This is how it sits now:



And this is what I've got the starter cover looking like, but it keeps looking better in the pic's than it really is. It has blackish spots on it that look like it's still tarnished, so not sure what I'm doing wrong with the cutting and polishing, so I'm just gonna leave it for a bit and try again down the track.





There's four pic's coz I'm hoping at least one will show up what I mean...

I'm also now having an issue with my camera, keeps saying flat battery although I've replaced the AA's and also today the little watch battery also... really don't want it to die as then it'll have to be phone pic's which really suck.

Anyways, next I'm gonna get my mate to BBQ the motor bits next weekend and then I can start engine reassembly... yeehaa!!!

 

[Macguyver]

Things are definitely looking good Pete!

As far as the black spots on the cover go, it is possible they are oxidation on the metal itself. Did you use a polish like autosol, or other oxide removing polish, or was it just a rubbing compound type polish?

I had some chrome bits that would not clean up like yours, then I polished again with autosol, and it took the spots right off. It appears that the cleaning wax I was using didn't remove the oxidation, it just removes physical gunk from the parts, and does nothing for the oxidation.

Just a thought, Keep up the great work Pete!

 

[Guest]

Thanks for the tip Mac.

It does look like oxidation to me for sure.

I used a wire wheel first (was covered in surface rust initially), then used the cutting compound and sisal wheel, followed by buffing with a stitched rag wheel, then polishing with a calico wheel, at least I think that's what it's made of.

I'll give it a go over with Mothers by hand and see if that makes a difference, you could definitely have a point there.

 

[herostar]

looks like it's coming along good

Lets see some pics with the bodywork mocked up!

 

[Guest]

Sure is Chris, can't wait to start getting the engine back together.

I haven't started hunting around for a seat or rear mudguard yet so not quite ready for a mock up.

I'm also thinking of saving toilet and paper towel rolls so that once the engine's together I can mock up an exhaust how I want it, should help with making it.