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1981 GS450E Rebuild

  • Thread starter Thread starter Guest
  • Start date Start date
I just chucked a bunch of natural light photos over in my paint thread...

And I took a random shot of the bike how it stands at the moment too, just coz I could:



Then tonight I did part two of the clean up... I have a clean work bench finally!



Didn't take me long to get the next lot of work on there though.



The framework of the tail piece, tail light bracket, cut down centre stand bracket, and brake line mounting bracket will all get some POR 15 Blackcote.

I should be able to do this at night with no dramas at all...
 
I pulled the booth down last night so the tank etc. are now residing in their temporary new home under the work bench to keep them nice and safe. The tail piece is of course waiting for the frame work to be painted with the Blackcote.

And speaking of that, I got the exhaust bracket off the bike last night and got all the bits waiting for Blackcote cleaned in Marine Clean and sanded ready for Metal Ready. I didn't stick the tail piece in the Marine Clean obviously, I'll clean that one down gently by hand...



I also ordered a headlight sight unseen from the local Yamaha dealer which is a lot closer than the Suzuki one. 7", side mount, standard H4 bulb, and chrome. I wanted black rather than chrome but that's all they have. At least the hunt should be over...

Emgo seems to be a no-go here in Aus and I suspect they don't meet ADR requirements which is no good to me anyway.
 
Pete, I know all about having a big work bench and nowhere to work, amazing how the stuff just piles up.
I spent a great part of this last Sunday doing garage clean up and trying to reclaim some work space on the bench. :rolleyes:
I soooo, need more sheving and storage space.
 
i like your work bench setup pete, mine gets so much crap on it and no matter how many times i clean it 10 minutes later its just as bad. Doesnt help that i have the crankshaft from the kingswood taking up a large part of it.
 
Flyboy said:
Pete, I know all about having a big work bench and nowhere to work, amazing how the stuff just piles up.
I spent a great part of this last Sunday doing garage clean up and trying to reclaim some work space on the bench. :rolleyes:
I soooo, need more sheving and storage space.
Click to expand...

Yeah it is isn't it? While doing that painting, I reckon I had a total of about an inch square of working space available, and nothing I was doing involved the work bench!

I don't think there is ever enough work and storage place... ever... if you get a bigger workshop with more space, you'll just fill it with more stuff ;)

Woodsy said:
i like your work bench setup pete, mine gets so much crap on it and no matter how many times i clean it 10 minutes later its just as bad. Doesnt help that i have the crankshaft from the kingswood taking up a large part of it.
Click to expand...

Cheers, Josh, and don't worry that's what mine's like. I actually have a work bench that goes in a U shape that in theory means I should have about 5 or 6 metres lengthwise of work space, but I lose the left side to tools and other crap, the right side to the bench grinder and little paint booth thing, which just leaves me the middle bit which I keep messing up... one day I'll get organised and have it all available, probably when I don't need it... hahaha
 
Well, first off, didn't get the call back to say my headlight's arrived, so I'm not sure if that means they forgot to call or it's not there. Might drop by in the morning to see. If all else fails I can have a look at some hand grips...

And tonight I got the first coat of Blackcote on.

Did the Metal Ready thing first off:



Got the little bits hung up in my little temporary paint booth area that sits semi-permanently in the corner of the work bench and cleaned everything with wax and grease remover:



And I popped some masking tape above the side mounts for the tail piece just in case I got a little enthusiastic with the paint brush:



And first coat on:

 


I believe I may have time for the second coat tomorrow morning which would be nice. That means if next Saturday is bike day again I should be able to mount some of this stuff again.
 
ah nice progress.
i am glad to see it looks good, can t wait to see some pictures under the sun Pete! :)

nice garage cleanup too, well i think we all have to go through that once in a while...
*have a shy look at mine...oh god...*

keep up the good work.
 
Hoosier Daddy said:
Good on ya Pete!
Click to expand...

Cheers Hoosier! One step at a time 'ey?

Etcheberri said:
ah nice progress.
i am glad to see it looks good, can t wait to see some pictures under the sun Pete! :)

nice garage cleanup too, well i think we all have to go through that once in a while...
*have a shy look at mine...oh god...*

keep up the good work.
Click to expand...

Thanks mate! I really hope we get some sun soon when I can get them out there to polish.

And yeah, the garage and work bench were really getting on my nerves, but now it's all workable again :D
 
Very limited time today but I got the Dynatek plate notched for the oil pressure switch and got the second coat of Blackcote on.

There's now plenty of clearance for the pressure switch:



Second coat on:



And finally I'm going to toss the old pipes:



The headlight should be here Monday or Tuesday...
 
Ducked up the road this avo to pick up some electrical odds and ends:



The inline mini blade fuse holder and mini fuses are for the voltage monitor if I ever get around to finishing and mounting it.

The 6 way plug fits the old R/R on the bike, so I figured I can replace the plugs on the new R/R so I don't have to hack the harness.



I had a closer look at the R/R wiring tonight because it's non-standard already:



Turns out that the R/R that's there and faulty seems to have a sense wire already which you can see is the brown wire connected to the indicator relay. Cool, makes my life a lot easier.

I double checked on the correct diagram to ensure it wasn't like that from the factory:



So, first off, cut the plugs off then stripped and tinned the wires on the new R/R:



And crimped the male plugs on and soldered:



And inserted in the correct order into the housing:



I decided I'd replace the housing on the connector on the harness because it doesn't have the latch on it, so I used a thin piece of wire to unclip the connectors and slide them out, and here's what I saw:



PO has done the right thing by bypassing the headlight circuit with the stator direct to the R/R and has put a newer R/R with a sense wire on it, but then proceeded not to use a spot of solder when doing the plug...

So I cut the connectors off, stripped, tinned, crimped, and soldered:



And inserted in the correct order into the housing:

 
They're now a nice firm latching pair:



And I figured I'd best check the modification on the indicator relay seeing as they didn't use solder:



They soldered that one!

Next up, seeing as I'm using the Dynatek ignition and don't need any room for a bulky ignitor or whatever, I can finally ditch that horrid electrics tray I made.



Then I need to make another one for these bits and the R/R:



To get mounted back in here again:



I'm going to use a bit more of that 2.5mm alu. I have left over from the fork brace to make a new tray up.

Measured it out and got the component placement sorted:



And underneath will look something like this:



I also ordered a battery and trickle charger this morning, so I should be able to power it independently some time this week I hope...

I also emailed about the brake disc and pads to see if they keep them in stock.
 
very nice indeed,
you seem in a comfort zone with wiring/soldering, don t you? :)
 
Etcheberri said:
very nice indeed,
you seem in a comfort zone with wiring/soldering, don t you? :)
Click to expand...

Thanks mate! Reasonably comfortable... did a bit in college and used to play around with electronics a bit when I was a bit younger so I've had a bit of practice over the years :)

Unfortunately my hand gets a bit shaky doing delicate work, so some of my joints get a little dodgy...

Woodsy said:
you polished the tank yet?.... :P
Click to expand...

Errr.... nup! Ha

House mate picked up 1500 and 2000 grit wet/dry paper today though... just need to figure out what I'm doing for cutting and polishing...

Leigh said:
So damn close, Pete.
I'm hanging on every photo..
Click to expand...

Yeah very true Leigh, damn close alright!

Battery and charger shipped today according to eBay updates and Metalgear has my disc and pads in stock so the house mate is hoping to pick them up tomorrow for me.

Headlight should've arrived today or maybe tomorrow so hopefully they'll call to tell me so I can pick it up on Saturday and also have a look at their hand grips and I also should try to get some fuel and vacuum hose as well.
 
And for tonight's effort... I got the electrics tray mostly done and I must say it's about 300% better than the other one even if it's not perfect.

Cut the tray out of the sheet of alu., taped the template on, and drilled the pilot holes:



Looks like it will fit nicely:



And ignoring the ragged pilot holes, you can hopefully see where I managed to get a nice chamfered edge on the whole tray with a file and get the corners somewhat rounded off as well. The old tray was hard to get smooth because I cut it out with tin snips, so using a hacksaw on this one made it a lot easier to file smooth:



Then I realised I'd missed a place for the main fuse holder, so figured it was best going at the front:



And it should sit something like this once I drill the right size holes and get it mounted up:



Plenty of room on top for the various bits of harness that need to go in there and the R/R should hopefully get a nice cooling air flow where it sits underneath. That's also the reason I'm using the 2.5mm alu. sheet; for some enhanced cooling of the R/R.

I should be able to get those holes drilled and get it mounted next time I'm down there and I can then get started on neatening the rest of the harness again and getting the Dynatek re-installed properly.
 
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