1981 GS450S frankenbike rebuild

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No manufacturer specific colour. Just something available from the local hardware store. As I'm spray painting for the first time I decided to use cheap rattle cans for painting, so I can focus on getting all the other steps right. With these rattle cans I don't feel too bad when I cock it up and have to redo something. If nothing else, it has taught me patience. Not sure what would qualify me to move up to better quality paint, but it's not important right now.
Didn't know any of the Suzukis were green before, but I didn't research whether that had been the case. Will do now. If it happens to come close it'll be a lucky coincidence.

 

[Guest]

Suzuki T500 Titan green and white, similar idea to yours
http://www.bikesrestored.com/14407/suzuki-t500-titan-1970-2/suzukit500-1970-3-4/

 

[Guest]

In the last 2 weeks some good news: the replacement pistons and valves arrived. So it was off to the engine builder to get the barrels rebored for the 73.5 pistons. Apparently this bumps the total cc to 480. Cylinders back in place and timing gear all in. So this brings me to next few questions:

The exhaust cam has the #2 mark missing (see pic) and I wanted to confirm the number of pins from #1 to #3. According to the manual I have, the should be 18 chain link pins from #2 to #3 marks. And from what images I have found online, it seems there would be 8 pins from #1 to #2 mark. Giving me a total of 26 pins from #1 to #3, and that should get my timing right. Can anyone confirm the number of pins from #1 to #3 mark, that would be a big help.

Second question: with regard to the valve clearances. The manual indicates clearance between 0.03 and 0.08mm. Can anyone confirm this? The measured clearance I got on my valves are:


Right Side:
- In 0.1 - 0.15 mm
- Ex 0.35 - 0.40 mm

Left Side:
- In 0.15 - 0.2 mm
- Ex 0.1 - 0.15 mm

These numbers seem a long way out so wondering if this should hightlight some special considerations. Or is it just a case of measure the shims that are in there and get suitable replacements.

Now to find shims locally

 

[Guest]

Brake Adapters

Brake Adapters

It been a while since having moved forward with this project, but finally got the adapters in place and mounted.
Simply used a 12mm plate of 6082 Aluminium Alloy and cut out some shapes. Thanks to a friend who mocked up a plate and 3d printed a template, this was fairly straight-forward.
Just a bit of drilling and sanding resulted the finished alpha version.
Given I have no specialist tools for some things, I used a hacksaw to cut out the rough shape and then a drill to perforate the plate along the basic shape. Next time I think I will spend a bit more effort trying to find an alternative solution.
Maybe find someone with a waterjet to just make my life easier.

Marking out the shape

And all cut out

Once the shape was roughed out, I went at it with an angle grinder and some files. Took a bit of time to get through this, but didn't turn out half bad in the end:

My one concern is where the caliper slide pins have been threaded into the plate. As you can see from the above picture the pin only threads through about halfway, so I will get some new pins made up at some point that fully engages the available threads in the plate.

But for the moment, as the bike is not moving, they will do.