1981 GS450E Rebuild

[Guest]

Actually I'm not posting anything, search answered already, and I will get a replacement seal. More waiting...

 

[Flaming Chainsaws]

What the heck Flaming Chainsaws was doing riding in this I don't know.

Well... That morning there was no snow at all and the bike is my only transportation. Three hours later the streets were filled with snow. I had to get home somehow and I couldn't just leave the bike stuck in the parking lot for the whole Thanksgiving week. If I left the bike there, the parking lot would have been locked exposed to snow and it would have gotten towed. My school has a very strict policy; No parking after 3 PM. So I took the risk . And no, it wasn't cold at all.

Your making some good progress, Pete. I wanna see it all together, especially the blacked out motor. I have the same plans .

 

[Guest]

Well that was just too easy today.

Called my local dealer... looking for this oil seal. Yes, we have three in stock for $9.99. I'm lying on the floor in shock. In stock and not expensive.

So I rock up, and while I'm here can you check for the piston circlips as well? Yep, have them in stock too, $2.30 each. Almost on the floor again, but that would be embarrassing in the store.

So, end result is I don't have to wait



Shifting shaft oil seal in the bag, four piston circlips (for mounting on rods) stuck to the outside.

Next stop when I'm a little more sober (few beers and sparkling white and red today) will be getting the bottom crank case ready to roll and popped onto the top crank case. Can't wait...

 

[SVSooke]

Lucky you,it happens.Not very often but it does.
FC ; I was not very serious in that post.Been following your thread to,I know your situation.Been bike only to,most of the year it`s not that bad.When it sucks it tends to suck real bad.

 

[Guest]

I remember years when I was bike only too actually, although no snow here.

At the time I was taking a temporary deviation from my normal career to drive a taxi, so riding home at 4am in rain in the middle of winter after a 12 hour shift wasn't terribly fun.

On the other hand, I really miss having to go everywhere on two wheels because that was my only transport. Forced me into having an enjoyable trip nearly every time (except of course the rain in winter above)

 

[Guest]

Did a little bit tonight but not much. I have a couple of threads in the twin cylinder forum I need some answers on before I go much further. Don't want to put the crankcases together only to find I've sealed the bearings to the cases and haven't replaced two O rings...

Anyways, first up I committed a bit of a tidiness as the work bench was getting a little cluttered and I needed some more room.



Much better!

Time to replace that old shift shaft oil seal as it's looking a little dodgy and there was definitely some crud in that area when I dismantled the engine originally:



Glad I did! See what was hiding behind there? I'm sure it's not a big deal but best to get rid of that now while it's apart than have to take it down again later to replace it:



Gave the lower crankcase a good run through with kero to make sure it's all cleaned up ready to roll:



And got the new shift shaft oil seal in as well:



So, hopefully I get some answers to my other threads real soon and I can get those O rings replaced, then get the crankcases together.

Once that's done I'm a rockin' and a rollin' baby...

 

[KC1908]

Pete,

Haven't done a 450 but heaps of EFEs(GS1150) and there is an o ring between the two cases for the oil passage and one at the bottom of the bottom case between the case and the sump. Should be a recess there for it to fit in if it is the same as the 1100 and 1150. Good luck.

Ken

 

[Guest]

Cheers Ken, are you talking about number 19 in the diagram below?

If so, does't work for the 450 unfortunately. This is the fiche in my other thread, number 20 is what I'm trying to find to replace:

The O rings are something like 3 or 4mm diameter, so very tiny.

 

[Guest]

Completely forgot I hadn't put links to my other technical threads here:

O Rings question:

http://www.thegsresources.com/_forum/showthread.php?t=168690

Crankcase sealant question:

http://www.thegsresources.com/_forum/showthread.php?t=168689

Right... so... I made some progress again last night

First thing I did was go back and give the upper crankcase half a double check, made sure everything still spins freely, and put a little engine oil on the transmission gears.

Then, made sure the lower crankcase was still all clean then put in the cleaned up bearing inserts:



Then, after getting some advice from Ed (Nessism), I used a small paint brush to get the sealant around the lower crankcase as thin as I could while still enough to seal the oil in there. I also used a tip from Don (Suzuki_Don) and referred to a Kawasaki diagram he put in my other thread to make sure I was covering the right surfaces. I was pretty sure I knew what to do as far as that was concerned, but it's always good to double check, and I mainly was concerned about getting the sealant too close to the crankshaft and counter balance shaft bearings.

I also put another thin film of moly lube on the bearing inserts.

So, sealant on:



Next up was the big moment... getting the lower crankcase on. It needed some light persuasion with a rubber mallet to start with, then I must admit to doing the "wrong" thing and using four of the bolts to pull it down properly as the mallet was making too much noise for late at night. I did at least make sure nothing was binding before doing that though.

Together at last:



And the most tedious part of all, getting all the bolts in and torqued up in the right order. I also whacked some blue Permatex thread locker on to make sure they won't come out in a hurry:



Then I got the screen on, once again with thread locker on the screws:



And finally, started making sure the sump cover was all ready to go, but ran out of time before being able to get it on. I still need to finish getting the old gasket remnants off, then it's right to go:



All in all I'm pretty happy with that, and I did also go back and double check the crank and counter balance shafts spin like they should and I can change easily through all gears too, so looking good!

I did get some sealant squeezing out the sides so I'll need to go back and clean that up too.

Unfortunately you can see my crap paint job showing up on these pic's too, but thankfully it's the bit noone should see... when painting with high temperature paint, make sure your prep work is good, then do it again, otherwise you too will end up with a result like this...

 

[Guest]

Didn't think I'd get an update in this morning as my ISP was having some dramas, but alas they fixed it just in time...

So, sump cover and 12 cleaned up bolts ready to go:



That horrid green gasket on (yes I can see the horrored guffaws of Athena haters everywhere, and I still wish I could've found a OEM gasket set):



All buttoned up with thread locker on the bolts:



And even though they don't say to do it yet in the manual, sump plug in just in case I forget it later on when I go to fill it with oil:



Flipped over and the last crankcase bolt in, also with thread locker:



And there she sits on the work bench at last, up the right way for the first time in years:



Next up, shiny new clutch push rod oil seal and the oil seal and bearing retainers cleaned up:



And the new oil seal in place:



I drifted it in gently with a socket driver about the same size as the seal diameter as it was quite a snug fit, which of course is a good thing for an oil seal!

 

[Guest]

And trouble! Oil seal retaining plate is there, but I seem to be missing one of the bolts. I can't find it in any of my tins containing the crank case bolts and bits, nor any of my early disassembly unlabelled tins either.

Mind you, I got this off so long ago it's possible I ruined the bolt and hadn't kept it to remind me to replace it...



At least I got the bearing retainer plate on, thread locker on the screws too:



Next up, pulled the two oil jets out from the top to ensure the O ring location is correct, and yep it is, that's where they go. The jets are a press fit, not threaded, so I reckon it's a must to replace those O rings, will do that tonight or something:



And the jets come from either end of the cylinder openings:



So that's where she sits now. Next up is replace those jet O rings and get the gear changing shaft etc. in.

Guess I'm also now ordering a very small bolt from the dealer...

 

[Guest]

Ok, first off, called my local dealer this morning... Hi, looking for 1 bolt and 3 O rings, yes we have those in stock... what? I said yes, we have those in stock. Awesome, will pick them up Saturday.

I think they must know what I'm looking for or something... more likely they use the same parts on lots of models.

In a nutshell, that means Saturday I should be picking up my missing bolt, the two O rings for the oil pump, and the O ring for the gear indicator sensor.

Anyways, back into it tonight, and first thing was those pesky O rings on the jets.

I'm glad I replaced them, because both felt rather hard and one had started to perish a little. I also discovered the right hand side one was partially blocked, so gave that a clean out with a thin bit of wire.

Back in place with new O rings:



Next up, cleaned up the shift shaft:



And then cleaned up the spring for the detent plunger on the shifting drum as well as the neutral pin, spring, and bolt:



Got the neutral pin, spring, and bolt installed:



Then I got the shifting shaft installed and the spring for the detent plunger:



I popped the shifting arm on the end of the shift shaft and was able to shift through all the gears no troubles, although it's a little difficult because there's no leverage without actually mounting the linkages on the foot rest.

And that's where I stop tonight, because I'm unexpectedly up to the clutch already and I haven't printed out that part of the manual!

Will do that at work tomorrow, then heading out tomorrow night with my wife, so don't expect to get back to it until maybe Sunday or Monday night.

Making some good progress finally though

I also thought I would've heard back about the cylinders and head by now, will give him a call Monday or Tuesday if I haven't heard by then. I'm on a training course on the 13th to 15th so won't be able to take his call if it's not until then...

 

[davidduarte]

SNIP

And that's where I stop tonight, because I'm unexpectedly up to the clutch already and I haven't printed out that part of the manual!

SNIP

Are you using the Haynes pdf? I have a Clymer (I have the Haynes and Clymer; I consider the Clymer the superior manual); if you need a section pm me and I'll scan it into pdf format and email it to you.

 

[Flaming Chainsaws]

Are you using the Haynes pdf? I have a Clymer (I have the Haynes and Clymer; I consider the Clymer the superior manual); if you need a section pm me and I'll scan it into pdf format and email it to you.

It would very nice if you could scan the whole thing... Please? ray: Then let BassCliff host it on his website so that we can all see it. Although that will take a lot of time.

 

[davidduarte]

It would very nice if you could scan the whole thing... Please? ray: Then let BassCliff host it on his website so that we can all see it. Although that will take a lot of time.

maybe if you were in Australia AND rebuilding your engine, I'd think about it. If you want a Clymer, you can go on Amazon and order one. I probably shouldn't offer to copy a few pages, and I would only think about scanning the whole thing if I knew for certain that it was out of print.

 

[Flaming Chainsaws]

maybe if you were in Australia AND rebuilding your engine, I'd think about it. If you want a Clymer, you can go on Amazon and order one. I probably shouldn't offer to copy a few pages, and I would only think about scanning the whole thing if I knew for certain that it was out of print.

Sorry if I offended you, man. I was just saying.

 

[Guest]

Thanks for the offer David, but thanks to the kindliness of our very own and local Suzuki_Don, I have a PDF of the Clymer manual. I looked around at prices to buy one as I prefer to have a manual in my hand, but over here the prices are just stupid for them.

I have a Haynes manual that I bought many years ago, but that resulted in me stripping a thread in the crank case, so I've stopped using it except for referring to pictures to get a clearer indication of what the Clymer is talking about.

Allen, I'll see if I can dig out the link for you.

 

[Guest]

Ok, got the bolt and O rings yesterday, so oil seal retainer, oil pump, and gear position sensor can all go back in now. I also printed out the clutch section of the manual, so I can clean that up and get it back in also.

I'm very quickly approaching the point where I need the cylinders and rings, so hope they're not too far away! I still need to clean the old carbon off the pistons yet though and get a hone also.

On another note, for some reason I wanted to get the odometer reading from the instruments. I think it was actually for another thread, but it's 94264.9 kms, so it has done a fair few. I would've only put 8000 - 10000 on myself. And yes, that's kms, not miles

Also, for Leigh's and my benefit, the light switch is on the right hand controls, so I should be able to use a GSXR left switchblock for the choke too, which would be great if I can figure out how to make the change.

Anyway, hopefully some more progress tonight or tomorrow night.

 

[Guest]

Back at it tonight... and bugger! The circlip that holds the sprocket on the oil pump is dead. Looks like when I removed it it lost its tension, so that needs replacing, and I need that on before I get the clutch on.

I wonder if all circlips are the same and I can get one from a hardware? Otherwise it's yet another trip to the dealer, they must be getting sick of my tiny little orders by now...

Anyways, this is what I did get done...

Oil seal retainer in with the new bolt, and gear position sensor in with the new O ring:



Idler gear for the starter in:



Oil pump in with new O rings, but no circlip to hold the sprocket on:



Thread lock went on all the bolts and screws too of course.

And it's hard to show what the circlip's like, so this is the best I could do:



Once I get that circlip sorted, it's clutch time.

Besides doing this tonight, got the garden shed finished up today too, had to bolt it to the brick wall it's up against and get some timber in there to hang stuff off. Also put two sets of shelves in, one at each end.

I'm quite amazed at how much has gone in there so far, yet there is still tons of room for more stuff to go in, so I may just get a nice place in the garage to put my bike without having to take a car out first every time.

 

[Woodsy]

Its slowly coming together, I had a buggered GSX450S that came with my 250 but the engine was really tight and the bike was partly disasembled so i sold it, i would of liked the extra 200cc though.. hehe

What about something like this? Dont mind my crude drawing. Shorten the Tail, put a megafone exhaust on it, wire wheels, paint it, obviously alot better than my drawing.. lol