My 1981 GS650G Thread

[Skateguy50]

You left something off the to do list.

RIDE!

hope you get it on the road soon, looking great. I say you shorten the list to the things required to run, and save the other mods for next winter.

 

[Macguyver]

Its lil over 10 hours (non stop) from my place to Formosa, Ontario. My buddies said they wanna plan a road trip with me when I'm home lol.

Thanks, and you are more than welcome to visit the little village of Formosa, just give me some advance warning so I can stock up on bevy's.

You left something off the to do list.

RIDE!

hope you get it on the road soon, looking great. I say you shorten the list to the things required to run, and save the other mods for next winter.

I have been paring down the list and I hope to have the required for safety stuff done in a week or two.

:-$ Don't tell the local LEO's, but I may have to go for a few "test" rides before I get the safety done. I will need to cure the ceramic header paint somehow, and idling the bike in the driveway for an hour just won't get the pipes hot enough.

Well, I'm off to grab some grub, and then get to work on mounting the headlight.

 

[Theo]

The bike is looking good mac. Nice to see it finally outside I bet. I can't wait to do the same.

Theo

 

[AF_Bill]

Right on Mac. What style of headlight ya goin with? The oval style? I would suggest maybe a dual set up. Maybe 2 small fog light type lights. Just a thought man.

 

[Macguyver]

Yearrrggghhh!!!!!

Yearrrggghhh!!!!!

Wouldn't you know it, I put the bike out side, and this is what happens.

It's been raining cats and dogs since about 4 AM. Oh well, I guess this is nature's way of getting me to finish up some indoor projects for the bike, like the indicator assembly rework.

Surprise company showed up last night as I was finishing supper, so I was unable to accomplish any work to mount the headlight.
As far as the headlight goes, I think my decision problem is because I have too many choices:

I have another oval type light the same as the one in the pic reconditioned, so I may still end up going dual with them.
Since I won't be able to mount any of them on the bike due to weather, I will think on it in the back 'o the brain while I work on other things.

I will update with pics later.

 

[AF_Bill]

Stupid internet blockin pictures.

I guess the first pic is of the rain or huge puddle lol. Really wish I could see the headlight right now. ARGH!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

 

[Macguyver]

Oval Headlight Update

Oval Headlight Update

Well, the sky cleared up enough to let things dry out a bit when I was working on the indicator lights, so I jumped outside to mount the headlight.

I think it should work out well, and look pretty good once I make the front fairing. I need to go pick up a new bulb though, I kind of broke the one I modded. Who knew the slightest sideways pressure on the little teat on the bottom of the bulb would cause it to snap off and go flying off like a rocket? Just glad I was wearing my glasses!

I should be able to make the form for the front fairing tomorrow, and hopefully get it fiberglassed too. Provided I don't get unexpected company like I did the last couple days. Not that that is a bad thing, it just messes with my bike time, is all.

Here are a few pics.

You know, the more I look at the bike, the more I think I need to replace the handlebars with ones less, well, chrome.
maybe I'll pop into the stealership this week and see what they can order in with a similar shape to them since the current ones are fairly comfy.

 

[Macguyver]

Dash Lighting

Dash Lighting

I had originally planned to work on making the front fairing today, but that was changed when a buddy showed up with a starter motor problem with his car. Once I had the starter motor changed, it started raining again.

So instead, I worked on the indicator lights for my redesigned dash.
I started by chucking up a 3/8" 4-fluted end mill in Ye Olde Drill Press, and machined off the plastic dividers from the original lighting holder.

First pass.

Second Pass.

At this point, I flipped the part over and did two more passes from the other side.

I then set about cutting some reflective dividers from some scrap sheet steel, and glued them in place.

Unfortunately, I was out of perfboard, so in my mad hunt for a substitute, I cut a piece of corrugated cardboard and poked mounting holes for the components in it with a very small jeweller's screwdriver, to make a very ghetto circuit board. I then populated the board with LED's and resistors, leaving a 1/4" gap between the board and components. Then I covered both sides of the board with 2 coats of activated fiberglass resin, and seated the components down into place.

Once cured, I trimmed the board to fit, and double checked the fit.

That is as far as I could go tonight since I need to get packing for a training course in Toronto which I am leaving for right after work tomorrow, so when I get back I can bend and trim the pins and make the necessary solder joints and wiring connections.

Once everything is connected, I plan on coating the back of the board with silicone to insulate it, and make it vibration proof, before final install on the bike.

I had my doubts on the choice of material for the board, but it yielded a decent result which fits in the dash piece very well, and is the same thickness as the original circuit board. It is also rigid enough that I have no worries about things moving around, and with the components held in place with the resin, vibration will be a non-issue.

I naturally have my concerns about the longevity of the "circuit board" material since it is only cardboard after all, but I do what I can with what I have available, and I will see how it holds up. At the least, it will be an interesting experiment into alternative perfboard materials. I would say I am earning my nickname on this one for sure!

 

[Bad Kaw]

Woooooooow!
Drive on!
-KR

 

[Skateguy50]

Looking good, how is the light spread with that oval one?

I am not sold on the look but have faith in your skills making a fairing that will tie it all in.

 

[Macguyver]

Can I get a second/third/Nth opinion on this?

Can I get a second/third/Nth opinion on this?

Looking good, how is the light spread with that oval one?

I am not sold on the look but have faith in your skills making a fairing that will tie it all in.

The light spread is fairly decent. Tall band, relatively wide. I was considering mounting both of them on vertically, with the lenses replaced with regular tempered glass to get a more uniform spread out of them.

Thanks for the vote of confidence, I appreciate it.

I am waffling again about the headlight though, I photoshopped this after thinking on it a bunch today. The mounting would be interesting to figure out, but I am sure I can do it.

It would utilize both projector headlights I have, in a stacked tube configuration. One for low beam, both for high beam.

I like the look and fit of this idea better than the ovals. However, I am still undecided since I haven't examined the idea of vertical ovals with the different lenses in depth. The more I look at the oval lights, the more I think they will look out of place since they don't imitate another shape on the bike. Whereas, the round projectors mirror several other pieces of the bike like the round end caps on the valve cover, the gauges, the stator cover, and other parts.

Plus, I think it looks pretty mean with the duplication of the accent vents from the side covers.

Yikes, I think I may have just talked myself into it.

 

[Macguyver]

Dash Indicator Lights

Dash Indicator Lights

Well since it has been raining almost non-stop since I put my bike outside, I needed something to occupy my time, so I went back to work on the dash indicator lighting. I still have to install some colored filters, and finish up some details, but here are my results so far.

First off, I labelled all of the wiring coming off of the original circuit boards before dissassembly, and the seperated them from the boards.

Here I resoldered the wires into their new homes for the top row of lights.
Then I soldered up the connections for the gear indicators.

Since the board I made can not use the original rubber isolator piece, I decided to coat the back of the board with red gasket maker. I simply ran a guide of masking tape around the board edge, and filled her up.

Here you can see the finished isolation, and the LED's I replaced the standard bulbs with. You can also see that the gaps for the lighting is fairly narrow, so the normal bulbs would never fit, hence the LED's.

Here are the boards in place.

Here is the light-up sequence. The LED's are really bright, which is good since I am planning to put colored filters between them and the back of the blackout for the gear indicators, which will dull them down a bit.

Well, that's it for now. I am picking up a pack of replacement 12V christmas tree bulbs today so I can complete the top indicators, and have spares, just in case.

I will update when more progress has been made.

 

[AF_Bill]

Mac, LOVE the photoshopped fairing. That'll look sweet once it gets done. As far as the lights go again, maybe 2 4in fog lights or something if the projectors don't work.

 

[Macguyver]

The World through multicolored glasses...sort of.

The World through multicolored glasses...sort of.

Mac, LOVE the photoshopped fairing. That'll look sweet once it gets done. As far as the lights go again, maybe 2 4in fog lights or something if the projectors don't work.

Thanks Bill,
I think I may modify the fairing idea a bit to run the lights side by side. I blame the fact I've been looking through the Triump Tiger Pics thread on ADV.

Don't get me wrong here. They are no Suzuki GS, but :-\\\.
Sure looks like a bike one could have a lot of fun on.

Anyways, back to the matter at hand.
I finally sourced the rest of the materials needed to finish my indicator lights redesign, and proceeded to cut and fit some colored filters for the lighting behind the gear indicator.

I needed to cut some colored filters from some theatre gels, but since I couldn't get any locally, I grabbed the next best thing for my small scale needs. A couple packs of colored index tabs did the trick nicely.

Here are some pics:

Yep, that should do the trick. Now I just need to install the 12V christmas tree light bulb I picked up, then seal the filters in place with some silicone and install it on the bike. I may double up the filters to shift the color more, not sure yet.
I'll sleep on it and finish this tomorrow night.

 

[Demonthrall]

you need black handle bars!!

Thanks for posting all of the pictures, very inspring. You have awesome taste with the olive/black combo. looks rugged.

 

[Skateguy50]

Pods or air box?

How did the pod covers come along, have you tested them?

Saw a thread that reminded me of your project, care to comment on that one? http://www.thegsresources.com/_forum/showthread.php?t=160041

 

[Macguyver]

you need black handle bars!!

Thanks for posting all of the pictures, very inspring. You have awesome taste with the olive/black combo. looks rugged.

Thanks, I am trying to keep her looking lean and mean. (or as lean and mean as a 650G can look anyway)

I have black bars on order, they should be in tomorrow!
That will give me the excuse to pull apart the handlebar area and install the dash indicators and finish up wiring in the new start switch,etc...

Pods or air box?

How did the pod covers come along, have you tested them?

Saw a thread that reminded me of your project, care to comment on that one? http://www.thegsresources.com/_forum/showthread.php?t=160041

Alas, I have not had my bike running yet, so I could not test the pod covers. I still need to finish some electrical, and then I can deal with the air filtration problem.

I have a new design for the pod air flow limiter, not sure if it will work yet. I have also been kicking around the idea of building a single oval filter airbox which would go right onto the carbs, with adjusters inside for each carb so they can be tuned individually as needed.
If people keep occupying my bike time with other work like they have been, I may not get a chance to get to the bike for a bit.

I have been making slow progress here and there when possible, but it's hard when I can't devote a large block of uninterupted time to working on bike stuff.

Oh well, I guess I'll just keep puttering away at things as time allows. I should hopefully be able to do a big update after this weekend if all goes according to plan.

 

[snowbeard]

just had to pop in and give my Congrats!! she's looking great! I like the fairing idea with the sidecover vents, carries thru nicely. good to see the care you put into all the little touches that most people who don't know every intricacy of these bikes will never notice!

you remind me of myself with the "I'll just pick this up and store it away, no idea when I'll use it but..." doesn't it just give ya a tickle when you realize what it was for years afterward and run and get it!!

can't wait for you to get some riding in, don't forget about the mold release on new tires, even tho you've had them awhile, they'll still be slippery for a good few miles

 

[Macguyver]

just had to pop in and give my Congrats!! she's looking great! I like the fairing idea with the sidecover vents, carries thru nicely. good to see the care you put into all the little touches that most people who don't know every intricacy of these bikes will never notice!

you remind me of myself with the "I'll just pick this up and store it away, no idea when I'll use it but..." doesn't it just give ya a tickle when you realize what it was for years afterward and run and get it!!

can't wait for you to get some riding in, don't forget about the mold release on new tires, even tho you've had them awhile, they'll still be slippery for a good few miles

Thanks, and the only problem with storing parts like that is...I need more room to do it effectively. My workroom looks like a freaking rubbermaid convention exploded in there!

I can't wait until the bike is ready for the road, but I must.

The bad thing is I keep getting other things on my plate to waste all of my bike time.

Maybe the next time someone asks for a hand working on something, I should tell them "No dough, no go", and raise my side-work rates to about $45 an hour, cash up-front. That should free up my schedule a bit, and get me some cash for bike insurance too.

Mold release, evil stuff. Good thing I live on a gravel road! That'll scrub it off pretty quick!

I hope to have a big update done this weekend, but we'll see how the side work goes tonight.

 

[AF_Bill]

$45 an hour!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Holy sh!t Mac! Thats STILL a deal and a half man. I dont wanna know what it is now. No wonder you've got people knockin on your door.

Can't wait to see the updates. I REALLY wanna see the fairing completed. Like I said before, I might be stealin some ideas of yours and the louvers on the fairing MIGHT be one of them lol.