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I got the mudguard and headlight installed last night, much better!
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
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I picked up a GS500 tacho on Thursday to use on the 450 but when I went to test it I discovered my ignition key wouldn't turn in the barrel. It was getting a bit stiff lately so not really surprised it stopped functioning.
I dismantled it to find three different issues, and it's a wonder it was working at all! The spring holding the little door stopping crap from getting in is broken which I guessed was the case quite some time ago, and of course the graphite I've put in over the years has turned to muck when combined with water and whatever getting in. The third wafer is bent way out of shape and there's no way it was moving at all, and the remaining wafers seem to be worn enough that they don't retract fully.
I'll shuffle the wafers I have around to get the best match I can for the key then I'll have to do a bit of filing on any that don't quite retract enough. Should definitely be fixable though.
Untitled by starpoint73, on Flickr
I dismantled it to find three different issues, and it's a wonder it was working at all! The spring holding the little door stopping crap from getting in is broken which I guessed was the case quite some time ago, and of course the graphite I've put in over the years has turned to muck when combined with water and whatever getting in. The third wafer is bent way out of shape and there's no way it was moving at all, and the remaining wafers seem to be worn enough that they don't retract fully.
I'll shuffle the wafers I have around to get the best match I can for the key then I'll have to do a bit of filing on any that don't quite retract enough. Should definitely be fixable though.
Untitled by starpoint73, on Flickrhuh! carry on ,Pete! but a little light lit in my brain-cave that you might be able to use the helmet lock as a source of wafers if you get in a pinch....if like me you never use it.
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Yep, same here, I never use it either! Although fortunately my wafer shuffle included some from a spare seat lock I have that is a little forlorn and I don't have a key for, so it donated a couple. Between that and a small amount of filing all is back in order with the exception of the little flap to keep the crap out as the seat lock uses a completely different spring for that. Now I can ride again, yay!
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Well I finally got it out for a decent ride yesterday after the changes so far.
Definitely more enjoyable to ride again and I had a blast, although encountered a couple of issues.
First one's a simple fix... my rear number plate had started to crack from vibration likely due to the weight of the reflector bolted to the bottom of it, and yesterday my favourite bit of twisty road was the final straw. At the top I discovered it had broken completely and was only being held in place by the height of the LED bolts I use for it. Ooops! It's cable tied on now temporarily.
The other is going to be a bit more effort to fix... essentially I have no top end power. Not having ridden beyond 70 to 80kph since May last year and only commuting, I've not picked up I have an obvious issue once the revs get up and the throttle is open. It sounds and feels like it's way too rich once I open it right up. I essentially had little to no top end in the faster sections yesterday, and it wouldn't even hold 100kph up a hill which it used to do with no fuss at all.
I guess it's time to look into putting an O2 sensor bung in the pipe finally and being a bit more accurate on figuring out the fueling.
I've never successfully removed the pipes myself yet so it won't be an immediate thing but I'll need to tackle that soon, and probably at the same time I should attempt to do something about the header dent and probably some VHT flameproof paint as well.
Untitled by starpoint73, on Flickr
Definitely more enjoyable to ride again and I had a blast, although encountered a couple of issues.
First one's a simple fix... my rear number plate had started to crack from vibration likely due to the weight of the reflector bolted to the bottom of it, and yesterday my favourite bit of twisty road was the final straw. At the top I discovered it had broken completely and was only being held in place by the height of the LED bolts I use for it. Ooops! It's cable tied on now temporarily.
The other is going to be a bit more effort to fix... essentially I have no top end power. Not having ridden beyond 70 to 80kph since May last year and only commuting, I've not picked up I have an obvious issue once the revs get up and the throttle is open. It sounds and feels like it's way too rich once I open it right up. I essentially had little to no top end in the faster sections yesterday, and it wouldn't even hold 100kph up a hill which it used to do with no fuss at all.
I guess it's time to look into putting an O2 sensor bung in the pipe finally and being a bit more accurate on figuring out the fueling.
I've never successfully removed the pipes myself yet so it won't be an immediate thing but I'll need to tackle that soon, and probably at the same time I should attempt to do something about the header dent and probably some VHT flameproof paint as well.
Untitled by starpoint73, on Flickr
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I decided to check the compression last night given the lack of top end and the results weren't good.
Number one has 120 PSI, number two only 100 PSI. Going by the manual 100 PSI is the service limit, but they should be 130 - 170 PSI, and if both cylinders measure under 130 PSI it's time for an overhaul.
So that sort of puts a bit of a damper on the refresh, at least I can still commute on it as it is for a while.
I've been contemplating the GS500 cylinder and piston swap for a while so something like that might be a way forward, but there's no budget for that for quite some time yet at this stage.
I'll still get the GS500 tacho on though as that'll be needed whatever I do.
Number one has 120 PSI, number two only 100 PSI. Going by the manual 100 PSI is the service limit, but they should be 130 - 170 PSI, and if both cylinders measure under 130 PSI it's time for an overhaul.
So that sort of puts a bit of a damper on the refresh, at least I can still commute on it as it is for a while.
I've been contemplating the GS500 cylinder and piston swap for a while so something like that might be a way forward, but there's no budget for that for quite some time yet at this stage.
I'll still get the GS500 tacho on though as that'll be needed whatever I do.
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I got the service done yesterday, standard oil/filter change and check valve clearances and so forth.
The only shim needing changing was number 2 inlet as last time I'm guessing I got the clearance a bit wrong as it was way out of spec (over 0.10mm) and had to go up a shim to bring the clearance back down to 0.08mm. All the other three were good.
There's no way too much clearance would lead to low compression though.
I looked down each spark plug hole as best I could with the valves open and the faces looked clean, no significant carbon build up I could see and same with the top of the pistons. Of course I can only see a small section of each that way so it's certainly not a guarantee that the valves are good.
I did a cold compression test and got number 1 with 140 PSI and number 2 with 150 PSI.
Took it for about a 20 minute test ride and did a hot compression test getting number 1 with 135 PSI and number two with 140 PSI.
Now I'm really confused! I did what I could in those 20 minutes to get the throttle open and revs up as much as possible and every time it felt strong, no drop of power like happened when the compression measured low. I'm guessing I have to get the engine hotter again to test this, then stick a bit of oil in to see if it's likely to be rings or head.
The only shim needing changing was number 2 inlet as last time I'm guessing I got the clearance a bit wrong as it was way out of spec (over 0.10mm) and had to go up a shim to bring the clearance back down to 0.08mm. All the other three were good.
There's no way too much clearance would lead to low compression though.
I looked down each spark plug hole as best I could with the valves open and the faces looked clean, no significant carbon build up I could see and same with the top of the pistons. Of course I can only see a small section of each that way so it's certainly not a guarantee that the valves are good.
I did a cold compression test and got number 1 with 140 PSI and number 2 with 150 PSI.
Took it for about a 20 minute test ride and did a hot compression test getting number 1 with 135 PSI and number two with 140 PSI.
Now I'm really confused! I did what I could in those 20 minutes to get the throttle open and revs up as much as possible and every time it felt strong, no drop of power like happened when the compression measured low. I'm guessing I have to get the engine hotter again to test this, then stick a bit of oil in to see if it's likely to be rings or head.
burning oil? unlikely to be rings without smoke from the pipes. maybe valve seals but again, more oil burned and soforth. I'd check it again warm and likely you are ok.
...Just a gremlin passing through.
...Just a gremlin passing through.
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Not burning any I can tell, and on the day I discovered the power loss I asked those behind me if there was any smoke, and the consensus was none observable. The Kat has valve stem seal issues with the loaned head, and people who follow me on that confirm blue smoke on down shifts, definitely nothing like that from the 450.
Yeah I think I'll just have to get it hot enough to have the symptoms and check again. Probably won't happen for a bit as we have wet weather starting in today.
Yeah I think I'll just have to get it hot enough to have the symptoms and check again. Probably won't happen for a bit as we have wet weather starting in today.
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OutbackPhil
Guest
Good read man. That cut down front guard looks the goods too, well done. I ended up mounting my mechanical speedo where the original ignition barrel sat and fits well and nice and tucked away. I'm living and working in Brissy now so I'll keep my eyes peeled for this bike zipping around. I've just replaced a dead stock CDI with a boyer bransden CDI and signal generator kit and the bike runs again so keen to get it back on the road. Cheers
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Cheers Phil! Funny you should post because I actually got a bit of time to do stuff yesterday finally. Definitely keen to see yours in the metal, that'll make three GS450's I know of in Brissie (including mine) as there's another fella who parks one just around the corner from me at work. What did you do with your ignition switch?
I finally got some time to work on a mounting bracket for the speedo and tacho yesterday.
I'm liking the non-symmetrical layout, and the speedo positioning means no interference between the clutch and speedo drive cables.
The big gap between them will also allow me to put a different ignition switch in given the state of the original now.
I've still got to figure out some sort of enclosure for the tacho yet, the bracket will get tidied up with some satin black, and I'll likely leave the speedo as is.
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
I finally got some time to work on a mounting bracket for the speedo and tacho yesterday.
I'm liking the non-symmetrical layout, and the speedo positioning means no interference between the clutch and speedo drive cables.
The big gap between them will also allow me to put a different ignition switch in given the state of the original now.
I've still got to figure out some sort of enclosure for the tacho yet, the bracket will get tidied up with some satin black, and I'll likely leave the speedo as is.
Untitled by starpoint73, on FlickrUntitled by starpoint73, on Flickr
Interesting to see a relay sitting there Pete; what's the for again?
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Hey Scott, those are the two headlight relays. They were bolted up under the old dash but at the moment simply get cable tied to the left dash mount. I'll be able to neaten them up again once I have the new bracket in place.
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OutbackPhil
Guest
You might be able to buy a gauge housing to fit the tacho. I remember a fair few years ago now looking into aftermarket 'go fast' stuff for cars and you could get autometer gauges etc and separate housings for them in black and chrome for people that wanted to mount them onto the bonnet. Super cool looking but super impractical.
I got rid of my original ignition barrel and bought an aftermarket one which I mounted on the left side of the battery box under the seat. Now the ignition is a single key behind your left leg when sitting. Works fairly well however I need to tighten it up now there's a bit of movement. It's a 3 position key but I've only bothered to wire up one way. I guess I could've wired them both up to do the same job but it works for me.
I've actually seen a GS450 parked up on Turbot Street in the city, along that mass of bike parking areas heading toward the storey bridge. It's a maroon colour, looks fairly original. Could be the 4th GS in the Brissy club?!
Cheers
I got rid of my original ignition barrel and bought an aftermarket one which I mounted on the left side of the battery box under the seat. Now the ignition is a single key behind your left leg when sitting. Works fairly well however I need to tighten it up now there's a bit of movement. It's a 3 position key but I've only bothered to wire up one way. I guess I could've wired them both up to do the same job but it works for me.
I've actually seen a GS450 parked up on Turbot Street in the city, along that mass of bike parking areas heading toward the storey bridge. It's a maroon colour, looks fairly original. Could be the 4th GS in the Brissy club?!
Cheers
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Ah good call, I'll have to do some searching around. I was simply going to bend some thin steel or aluminium but if something exists already that might be even better depending on price etc.
Sounds like a good solution to the ignition key! I did a similar thing with the Kat where it's mounted down by my right knee but can't find a suitable solution on the 450.
You sure that wasn't mine you saw?
How recent? I park on Turbot St although I park just before Edward St at the base of the big wall that leads up to Wickham Tce. The other 450 is blue and parks back around the corner in Albert St. I've only been parking there since April last year though as the company I work for moved buildings up from the Valley.
Sounds like a good solution to the ignition key! I did a similar thing with the Kat where it's mounted down by my right knee but can't find a suitable solution on the 450.
You sure that wasn't mine you saw?
How recent? I park on Turbot St although I park just before Edward St at the base of the big wall that leads up to Wickham Tce. The other 450 is blue and parks back around the corner in Albert St. I've only been parking there since April last year though as the company I work for moved buildings up from the Valley.
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OutbackPhil
Guest
Maybe that is your bike then. Probably 3-4 months back I guess, on the bike parking strip below that cliff face area. Caught my eye cos you don't see too many GS450s just parked up in the street like that.
Ah good call, I'll have to do some searching around. I was simply going to bend some thin steel or aluminium but if something exists already that might be even better depending on price etc.
Sounds like a good solution to the ignition key! I did a similar thing with the Kat where it's mounted down by my right knee but can't find a suitable solution on the 450.
You sure that wasn't mine you saw?
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Yeah that'll be mine alright! I park there every day, only time you won't see it there is if I'm on leave or if I've ridden the Kat, which you'll see there instead.
diptenkrom
Forum Apprentice
I know trhat this thread isnt the newest, but can you tell me what the exhaust is on this bike? i really like it, except i wish it was on the other side... But i have been looking for a high mount exhaust, and aside from building one myself, i have not seen any real options.
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