1981 GS450E Rebuild

[Guest]

Well in theory I got the clutch adjusted... I say in theory because spinning the rear wheel by hand with the clutch lever pulled in is quite stiff, but I'm hoping it's simply that it needs some running to free up properly after sitting for so long.

This is the first time I've tried the clutch since the engine rebuild.

I used Ed's steps from Oldrookie's clutch issue thread:

Step 1) Turn in the cable adjusters at both the handle bar lever and where the cable goes into the case. You want maximum cable free play at the lever.

Step 2) Loosen the lock nut on the adjuster.

Step 3) Turn in adjuster until you JUST START TO FEEL resistance then back the adjuster off 1/4 turn and tighten locknut.

Step 4) Check feel at the lever. There should be some free play at the lever, but not a whole lot. If you don't know what free play is please ask.

Step 5) If necessary, tighten the cable further until you have a small amount of cable free play with the lever released, but not much. You must have lever free play or the clutch will slip.

I also thread locked the tank badge screws in place because I'm paranoid about losing them before I decide if I'm going to paint the badges or leave them be.

I really hope I get the seat back on Friday... if I don't, I'm gonna be really pushing my luck to get this on the road before Christmas...

 

[Leigh]

Gaffer an old pillow to the frame if the seat doesn't show up..

 

[Guest]

Gaffer an old pillow to the frame if the seat doesn't show up..

Hahahahaha trust you

"Yes officer, I know it's not registered but it's safe and ready for a safety certificate... I just wanted extra cushioning"...

 

[Leigh]

You're in Queensland with the best police force money can buy.
What could possibly go wrong?

 

[Guest]

You're in Queensland with the best police force money can buy.
What could possibly go wrong?

True! At least I'm not in Melbourne... I'd be more likely just to get shot!

 

[Guest]

No call about the seat today... but I'm not surprised to be honest.

I did call the mobile safety certificate guy and he should be right for Tuesday if I book him in by Monday morning, so I really hope they ring me tomorrow to say the seat's ready... will call them around lunch time if I haven't heard anything...

Tonight I went in to tackle the chain adjustment and rear wheel alignment, but I shot a couple of pic's first to see if I like the tank badges the way they are or not.



I really need it in the sun to be sure, but I'm definitely leaning towards leaving them like that now, I'm really liking that raw look.

The it was chain adjustment/wheel alignment time.



Done, although I had a bit of a brain fart and adjusted the chain too tight because for some reason I thought it got looser when you put weight on it instead of tighter, so I'll revisit that next time.

 

[rustybronco]

Pete, love the look of the paint you used... especially on that brick

 

[cowboyup3371]

Nice pictures. Did you tie your rope onto something behind the back wheel when you did the alignment?

 

[Leigh]

So damned close now, Pete..

 

[7981GS]

So damned close now, Pete..

We can almost see the smile on his face!

Daniel

 

[oohsam]

Oh yeah!!!

 

[Guest]

Pete, love the look of the paint you used... especially on that brick

Hahaha thanks Dale, looks much better in the sun though, that flash makes it look terrible... mind you I didn't polish that bit

Nice pictures. Did you tie your rope onto something behind the back wheel when you did the alignment?

Cheers Scott. Nope, I stuck it in first so the rear wheel wouldn't rotate and used the chunky tread of the dual sport tyre to hold the rope. I had to have it lower than I would have liked though so it would go under the bar of the centre stand.

This is a method I've seen on here, definitely not my own invention

So damned close now, Pete..

For sure Leigh! Fingers are crossed the seat's ready and I can get out of work early enough to get to the upholsterer's...

We can almost see the smile on his face!

Daniel

Hahaha indeed!

Oh yeah!!!

Oh yeah indeed ... I wanna be where you are with yours... taking it for a spin!

 

[Flyboy]

All coming together now, on short finals now for sure, I am seriously chuffed for you Pete, the anticipation must be killing you, those little last minute tidy ups just seem to take forever and never ending, don't they.
I am just waiting for the maiden ride video, get on with it already....
You are formally dismissed from your ever patient temprement, mine is finished now.

 

[Matchless]

Pete mate,
I have not been on the forum much, being busy with various other things and noticed that you have the finishing line in sight!

Your bike looks extremely well and you have done a supreme job! I also give you 10/10 for a very thorough project thread!

After she is on the road you are most likely going to be bored out of your mind and will have to think of a way to spend all the money you are going to have extra every month.

 

[Leigh]

After she is on the road you are most likely going to be bored out of your mind and will have to think of a way to spend all the money you are going to have extra every month.

Fuel..

Yup, it'll be that simple.

 

[DrunkenChekhov]

I think you need a cotter pin big guy!


Looking great!

 

[Guest]

All coming together now, on short finals now for sure, I am seriously chuffed for you Pete, the anticipation must be killing you, those little last minute tidy ups just seem to take forever and never ending, don't they.
I am just waiting for the maiden ride video, get on with it already....
You are formally dismissed from your ever patient temprement, mine is finished now.

Cheers Stan! Yeah it's so close... I'm actually getting a bit nervous now... everything's hanging on the clutch being ok, although I think it is.

My nerves are mainly about the first ride in nearly 10 years... but damn I'm looking forward to it!

I definitely need to get video as I need to show Dynatek their ignition works as well

And don't worry, my patience is just about shot now... hahaha

Pete mate,
I have not been on the forum much, being busy with various other things and noticed that you have the finishing line in sight!

Your bike looks extremely well and you have done a supreme job! I also give you 10/10 for a very thorough project thread!

After she is on the road you are most likely going to be bored out of your mind and will have to think of a way to spend all the money you are going to have extra every month.

Thanks Andre! Good to see you posting, wondered where you'd been lately

It's very close now... mainly just a road test and safety certificate left after a couple of little finishing things. There are still some optional things I'd like to get done but they're not critical for registration...

As for the next project... it's a matter of deciding which one...



Or



Plenty of time before I need to make that decision though, and plenty of riding to be done too

Fuel..

Yup, it'll be that simple.

Yeah baby, now you're talkin!

I think you need a cotter pin big guy!


Looking great!

Thanks mate, I need three to be exact Front and rear axles and the drum brake stabiliser arm...

 

[Guest]

It was overcast when I got home from picking the seat up but still... me is a happy man right now

Tonight I got all those little fiddly things sorted.

Adjusted the rear brake and gear shift levers, fixed the chain adjustment and aligned the rear wheel again, adjusted the rear brake light switch, and finished cleaning the packing grease off the chain and lubed it for the first time. I also did my best to adjust the headlight height as well.

I also spent a reasonable amount of time sitting on the seat and standing back looking... I'm sure you can understand

All I need to do Sunday is get three split pins, check the tyre pressures, put some fuel in, check the ignition timing, and then I can check the clutch and gear shifting on the centre stand before rolling her out of the garage...

 

[Guest]

And Scott, just for you, here's some more detail on the rear wheel alignment

Axle stands with rope attached at the same height as you will have it sitting on the rear tyre. The concrete in my garage is a little slippery which is why I use the bricks to give the axle stands extra support in keeping the rope taught.



Rope goes 'round the back tyre, and the centre stand can get in the way if you don't do it right. I'm guessing on some bikes it will be almost impossible.



You can see where on mine it still touches the centre stand cross brace, but it only affects the rope vertically and doesn't impact on the alignment check.



Goes round the rear tyre:



And here's the trick. Get the front wheel centred and make sure the rope comes down each side of the front wheel exactly the same each side and making sure the width between the two ropes is the width of the rear tyre where the rope goes around it.



You can then tell by how close or far away the rope is from the front of the rear tyre if it's in alignment or not.

 

[cowboyup3371]

Thanks Pete. Looking really good and those pipes really seem to fit now