1981 GS450E Rebuild

[Guest]

Ok I did end up doing a bit tonight after all. I just concentrated on getting the alternator cover on as that's a bit of a quick win.

So, finished cleaning the gasket remnants off:



Some of my trusty threebond around each crank case seam as directed:



Locating pin in and gasket on, and it should be nicely lined up with the oil gallery:



And alternator cover in place ready to bolt on:



It's actually a bit of a challenge getting the cover on without disturbing the gasket as the gasket needs to stay lined up with the oil gallery and the stator has a tendency to get attracted to the magnets which makes it a little tricky.

And bolted on with my nice shiny new allen head stainless steel bolts from Z1 and with anti sieze on the threads:



I also gave it a quick once over with the polishing cloth to try to get rid of my greasy finger prints too (still too clean Charlie ).

And that's pretty much it for tonight, although I did start working a bit more on the gasket remnants on the right cover as that's the next one to go on.

And I just had a thought... my closest dealer is in Windsor which is a flood risk suburb... man I hope they don't go under and I hope my parts are able to make it safely there for Saturday! Would be a real shame if I get time to work on it and they're not there...

 

[Leigh]

Energex eh?
Small world, kind of.
I used to drive for O.D. and deliver the big Wilson transformers across the country.

That motor is coming together nicely now, looks sweet.

Oh, I finished my weekend fridge "rebuild"

 

[Guest]

Energex eh?
Small world, kind of.
I used to drive for O.D. and deliver the big Wilson transformers across the country.

That motor is coming together nicely now, looks sweet.

Oh, I finished my weekend fridge "rebuild"

OD? That sounds familiar but I can't put my finger on it... and yeah those transformers are rather largish. There's a substation in the basement of the building I work in because we're such a power hungry business, and it ain't no small beast... will be interesting if that fills with water today or tomorrow!

And cheers, I'm really happy with how it's looking. The polished covers and blasted cylinders/head should be a nice contrast to the cases. It's a pity my paint job is such crap, but the shiny bits should take the eye away from that

I like your fridge! Job well done

 

[Suzuki_Don]

There's a substation in the basement of the building I work in because we're such a power hungry business, and it ain't no small beast...

Well Hey Pete, this is one of the BIG MUTHA's that I look after during my spare time at work. V16 and check out the twin turbo chargers on top. It pumps out 2.5 megawatts when she fires up. And when you hit that air start you want to make sure you've got the doors open and ear muffs on.

.

 

[Guest]

That's a serious piece of machinery Don!

I haven't seen the generators at work so I don't know what they pump out or anything or how big they are, but I would imagine they wouldn't be small...

 

[Suzuki_Don]

Pete I should have had someone stand next to the generator to give some perspective as to it's size. But as a hint the dipstick is three feet long.

 

[Guest]

That's one long dipstick! That take a great big drum of oil I would imagine...

 

[Leigh]

Hey hey! Less generator, more bike!

Well, after my little photo at least..

 

[Guest]

Are you trying to imply that size does matter?

I was hoping I couldn't connect into work today so I could get the egine in the frame, but alas the VPN works so there went that idea... oh well...

 

[Guest]

Right, sick of water and floods and hearing about them, so back to bikes tonight, got some more done. Apologies if anyone sees this who is actually getting hit by water as I don't mean to be insensitive, but I've just had flood overload from the telly.

Anyways... finally happy I got enough gasket crap off the right cover, I swear that was glued on:



Locating pins cleaned up and in:



Quick double check everything is in order and ready:



Gasket on with a bit of oil on the lip of the oil seal:



And in place ready to bolt up with new stainless allen bolts:



And anti sieze on the bolts and all done up nice and tight:



Next, advance governor all cleaned up ready to go:



And on with some thread locker:

 

[Guest]

Cleaned up the dipstick and inspection bolt and in they went:



And this is how she looks, and yes Charlie, I did give it another once over with Mothers so it's still too clean



So, 100% definitely ready for the frame, time to move on in the meantime and start cleaning up the harness and getting the camshafts cleaned up ready etc.

 

[Leigh]

That is such a great photo..
It has me thinking things I should do..
Hmm, the kids don't need to eat as much as they do, really.
Surely they don't need both kidneys each...

 

[Guest]

That is such a great photo..
It has me thinking things I should do..
Hmm, the kids don't need to eat as much as they do, really.
Surely they don't need both kidneys each...

Haha cheers Leigh, but it does actually photograph better than it really is. That right cover is still quite cloudy, definitely not a mirror shine!

But you're right, kids eat way too much from what I've heard, and we have two kidney's for redundancy and there are plenty of people who've lost/donated one and are still fine

Now while I really can't comment on how your motor looks (still have seen no pic's yet), you should be able to get a pretty good shine going with it still in the frame, especially on the case covers.

My question is still about the oil filter cover as there's no easy way to polish it and I'm starting to think I should have sent it to be blasted with the cylinders and head...

 

[Suzuki_Don]

My question is still about the oil filter cover as there's no easy way to polish it and I'm starting to think I should have sent it to be blasted with the cylinders and head...

Pete what do you mean there is no way to polish the oil filter cover. If you really cant polish it then just paint it the same colour as the crankcases, it will just blend in and not be noticed.

 

[Guest]

Pete what do you mean there is no way to polish the oil filter cover. If you really cant polish it then just paint it the same colour as the crankcases, it will just blend in and not be noticed.

I should've clarified Don... if I really wanted to, I'm sure I could give it a polish, but there are so many grooves and lumps and bumps on it that it will take hours to do.

I may paint it yet as I still have plenty of the Black Velvet left... plenty of time to decide though as I don't really need it on until I'm about to fire it up and am ready to put the oil in.

 

[JEEPRUSTY]

I should've clarified Don... if I really wanted to, I'm sure I could give it a polish, but there are so many grooves and lumps and bumps on it that it will take hours to do.

I may paint it yet as I still have plenty of the Black Velvet left... plenty of time to decide though as I don't really need it on until I'm about to fire it up and am ready to put the oil in.

aha black velvet is an apt description
lovely finish on that

the frame looks greyish must be the light I am sure it would be black

 

[Guest]

aha black velvet is an apt description
lovely finish on that

the frame looks greyish must be the light I am sure it would be black

It is for sure! I was worried initially about how the matte black would look, but I'm sold on it now. I wanted a semi gloss or satin black for the motor, but this was the only black paint the POR 15 guys recommended for an air cooled motor.

The frame is definitely black and it's another POR 15 paint called Blackcote. Supposed to be a good tough top coat...

 

[Charlie G]

Haha cheers Leigh, but it does actually photograph better than it really is. That right cover is still quite cloudy, definitely not a mirror shine!

But you're right, kids eat way too much from what I've heard, and we have two kidney's for redundancy and there are plenty of people who've lost/donated one and are still fine

Now while I really can't comment on how your motor looks (still have seen no pic's yet), you should be able to get a pretty good shine going with it still in the frame, especially on the case covers.

My question is still about the oil filter cover as there's no easy way to polish it and I'm starting to think I should have sent it to be blasted with the cylinders and head...

I don't think I would want to ploish the oil filter cover. Looks like a PIA.

cg

 

[davidduarte]

Pete, what beautiful work! I can't wait to see how your bike will look when it's back together.

 

[Guest]

I don't think I would want to ploish the oil filter cover. Looks like a PIA.

cg

Nup, I'm definitely thinking paint... sending it away to get blasted seems like a bit of a waste of time considering it sits in behind the front wheel and guard.

Pete, what beautiful work! I can't wait to see how your bike will look when it's back together.

Thanks David, I'm really quite happy with it. Would be nice for a mirror finish but I'm just not that patient. I can touch it up later too.

I'm keen to see how it will look too