My 1981 GS650G Thread

[Guest]

There is nothing at all wrong with that.

It's the part that precedes that, and the attitude that's the problem.


I agree, if we all did the same thing, the same way, it would be a very boring world (unless you did it my way, of course ). The problems is that too many people just don't care about the effect their project is going to have on others. I know one guy that likes LOUD pipes on his bike. He put them on. He was asked to move out of his apartment complex because it was bothering all the neighbors. I used to know a guy that worked second shift. He would relax after work by watching a movie before going to bed. He had a nice surround-sound system and played it a theater-like volumes. His neighbors did not like to hear Star Wars at 1 am. The list goes on. Do what you want, but be considerate of others, too.

.

LMAO!!
Your the type of person that those type of people like to p!ss off.

 

[Macguyver]

Tunable Intake Shrouds

Tunable Intake Shrouds

Well, last night I was bored.
Since I couldn't find anyone who was home who had the tools I need to keep working on my tail light covers, I began some brainstorming on ideas for my scoot.
I really want to get rid of the stock airbox and use the pods I had purchased a while ago, but haven't purchased new jets to compensate for the higher air flow, so it's a no go situation...or is it?

The way I figure it, if the pods were made properly in the first place I wouldn't have to adjust my system to use them, I could adjust the pods to work with my system.

So I began making adjustable shrouds for them.
These are still in the prototype phase, so bear with me.
The black cover portion is bonded resin which slips over the pod element section. There is a hole in the center of the top of the covers for the adjustment hardware which I am figuring out. They will be able to be adjusted for airflow by varying the amount of the filter element exposed, to be changed by a mere twist of the cover. Then be locked into adjustment.

If this works, it will be a much better way to do pods on an older bike, with a heck of a lot less wrenching to get it to run right. Might be just the ticket to finally getting the carbs dialed in just right, even if I decide to rejet for performance later on, I would simply need to readjust the pods and away I go.

I will post more on this once I have the near final version ready to go.

 

[Macguyver]

Intake Progress

Intake Progress

More progress on the tunable intakes!

I did the math to figure how much of the filter element I needed to block off to create the tuning range and bonded some black speaker cloth over the element with some silicon used as the blocking barrier and the adhesive to hold the cloth in place.

This way, as the cone is twisted, it will open more or less free-flowing element. My hopes in this are to be able to use these pods instead of the stock airbox to open up more space inside the frame. I have plans for that space.

I now have the modified filters to the point that I can install them and conduct some trials to see if this will work for me. I know, I know, everyone is screaming "Just buy some jets already, and do it right!"
That is the plan, but I enjoy tinkering with stuff and I have two sets of pod filters here, and these are the cheap ones. So I don't mind if it doesn't work out well. I am going pods in the spring either way, and my jets should be here in a couple weeks, so I can jet as needed with either set of pods.

If these do work well enough, I already have a laundry list of changes I want to make if I make another set. I need to change the shape of the holes in the covers to more of a rectangular shape to make the most of the element available. To that end, I am taking a filter with me to work tomorrow so I can go to a few stores and see if I can find a set of plastic cups that could be modified to be used for covers. That will save me a lot of time, and it's a P.I.T.A. to make the covers the way I did.

I also need to pick up some hardware to make a locking handle too.

Curiosity won out again.

 

[Theo]

Man I'm really liking your build. And I have to say I'm really impressed with your ingenuity in regards to those air cleaner covers. How did you make them? Fiberglass molds? I sure hope they work out for you because then I'll be able to use the pods that came with my bike and not have to buy an expensive jetting kit. Keep the posts comin'.
-Theo

 

[Macguyver]

Thanks for the encouraging words Theo,

The covers are made from heavy 1/16" packing board. I made a template piece out of regular paper, and then scanned it and printed out templates which were then taped onto the packing board. The holes were cut out with a hole saw, and the rest was cut out with scissors.

I then taped the pieces into shape, and coated them with fiberglass resin. The resin soaks into the board to make it a fiberglass-esque like piece. Quite durable, yet still slightly flexible.

I have attached the template sheet if you are interested in playing around with this yourself. I need to do up some with a different hole in it, hence the urge to find some plastic cups to use instead. It takes a while to make the covers as is, too long to be enjoyable.

I will update as more progress is made.
TTYL,

 

[Skateguy50]

I like the thoughts with that, cause it seems lots of people buy pods thinking they look cool and could use the extra space then realize its not plug and play.

If I get your thoughts basically you will use the pods pretty much for looks alone cause you will be restricting the extra air they provide to tune it back closer to how the stock airbox delivers. I guess that makes sense if you didnt plan to do the exhaust over as well cause unless it can push the air out breathing more wont help much.

If you get a good system going for that send in the patent application, even if you never sell it get that in the books. I could definately see the marketability of such a thing.

 

[Macguyver]

Hello my freaky babies!

Hello my freaky babies!

I found some items of interest today while on lunch break.
I was cruising through one of the local stores and came across some black injection molded "cups". Lady behind the front counter looked at me kind of wierd when I pulled an air pod filter out of my jacket pocket.

All I can say is:
"OhmygoshthisisfantasticIcan'tbelieveIfoundsomethingthatwillwork!"

Yep, I finally found a premade cover to use for my tunable air pod filters.
Nice and thick too, so I should be able to machine out some sweet openings in them!

There is a bit of a gap between the cover and the filter element, but that's ok too. I have a few ideas which need that gap, so it should work out well.

The lady behind the counter asked me what I was doing, so I gave her the layman's version of what I am planning, and she told me a story about this guy she used to date back in the 80's that rode a Suzuki 850. She didn't know what kind it was, but she did say she loved the bike because "It was big, loud, and gave her good vibrations sitting on the back". :-s

Does anyone else think she was saying what I think she was saying? :lol:

Nevermind, anyways, I am going to play around with them tonight and see what I can get going with the new components, and will update with pics once I have something together.

Should be an exciting couple of days working on these. Figuring stuff like this out is what I was made for!

 

[Skateguy50]

I think she was looking for a "ride"

 

[Turtleface]

I've been reading this thread with interest, especially the taillight bits. With all the custom one-off stuff you've got going on, your nickname is very apropos. Nice work! Keep it up, and more pictures of taillight bits!

 

[Macguyver]

I've been reading this thread with interest, especially the taillight bits. With all the custom one-off stuff you've got going on, your nickname is very apropos. Nice work! Keep it up, and more pictures of taillight bits!

Thanks for the encouragement,
I have made arrangements to get access to a belt sander this weekend, so I will be making progress on the taillights and will post some juicy pics for you soon!

I am not feeling very well tonight, but I wanted to work on the bike, so I decided to do something about reducing the necessary throttle twist to reach WOT.

I have wanted to make the famous $1 throttle mod by Posplayr for a while now, but kept forgetting to pick up some pipe for it. I searched for a bit in my prototype materials bin and found some schedule 40 PVC conduit which looked like it would do the trick!

So I cut the piece I needed on the bandsaw, and decided to follow BWringer's idea of attacking the piece with a round file to create a different profile for the cable to ride in.

I think it turned out well, only took a couple of minutes to make. Then I discovered I made it too short! 6mm tall instead of the 10mm as laid out by Pos.

Ding Ding, round two!

Made the 2nd version, and took some 3M scotchbrite sanding sponge to it to clean it up a bit, and smooth out any file scratches in the groove. Turned out well, I am quite pleased with it. All I need to do for it now is to cut it to the proper length, but I can't do that until I install it.

Thanks go to Posplayr for posting this brilliant idea, and BWringer for the build on the idea. If only I can get my brain to work properly, I may even install it tonight. Can't wait to give it a shot, should really help with getting to the giggle zone on the throttle without having to reposition.

Thanks again guys!

 

[Macguyver]

Older video, initial bike start-up.

Older video, initial bike start-up.

I ran acrosss an older video from late spring/early summer 2009 of when I had just finished reassembly of my 650G after paint, carb dip, petcock, shock and seat replacement, and a miriad of other things I can't remember. I think the bike had literally 10 minutes of run time on it at that point since I didn't want to over-heat the engine sitting in a garage. I had yet to dial it in as it were. Very pleased with how easily it started, very pleased indeed. After adjustments, it only smoothed out even more.

I was running on no sleep after pulling an all-nighter putting it all back together so I am a little dopey in this one.

http://www.youtube.com/watch?v=pAGRR6glid8

 

[Turtleface]

I ran acrosss an older video from late spring/early summer 2009 of when I had just finished reassembly of my 650G after paint, carb dip, petcock, shock and seat replacement, and a miriad of other things I can't remember. I think the bike had literally 10 minutes of run time on it at that point since I didn't want to over-heat the engine sitting in a garage. I had yet to dial it in as it were. Very pleased with how easily it started, very pleased indeed. After adjustments, it only smoothed out even more.

I was running on no sleep after pulling an all-nighter putting it all back together so I am a little dopey in this one.

http://www.youtube.com/watch?v=pAGRR6glid8

Nice work! Funny how long you can go without rest while you're turning wrenches, eh? Just.....one....more...bolt....I find myself justifying 3-4 hours a sleep a night when I'm in crank it out mode. Speaking of which, back to work, these forks aren't going to assemble themselves.

The throttle mod is great, you'll love it. It'll make regular riding much more enjoyable as well, not just spirited riding. The extra spring tension you have to overcome (in my case, anyways) makes it easier for me to modulate the throttle in a precise fashion. Riding in less-than-ideal traction situations (rain, wet manhole covers, etc) is a good deal easier for me because of this. Great work on those rings, they look quite professional. I bet you'd sell out fast if you made a batch.

 

[Macguyver]

Nice work! Funny how long you can go without rest while you're turning wrenches, eh? Just.....one....more...bolt....I find myself justifying 3-4 hours a sleep a night when I'm in crank it out mode. Speaking of which, back to work, these forks aren't going to assemble themselves.

When I had the shop in Brampton I'd be working on a car to finish paint and often find myself getting out of the shop at 3 or 4 in the morning. Just cause it needed to be done if I wanted to bugger off early on saturday night. Or if I was doing mechanical work on one I liked, same deal. That's not including the usual emergency calls. Can be fun at first, can be a nightmare after a week or so steady! The gf hated it.

So how did the forks turn out? Doing seals/paint/both?

The throttle mod is great, you'll love it. It'll make regular riding much more enjoyable as well, not just spirited riding. The extra spring tension you have to overcome (in my case, anyways) makes it easier for me to modulate the throttle in a precise fashion. Riding in less-than-ideal traction situations (rain, wet manhole covers, etc) is a good deal easier for me because of this.

Funny, I was thinking that the throttle could use a bit more tension to increase consistency of control too. I don't think the tesion will change too much at the beginning of the twist since the profile is narrowest there, but I guess I will see. Almost seems "sloppy". I was also planning to sleeve the bar where the grip rides with teflon to make it as smooth as I can as well. Between the two, I think it shoud be much better.

Great work on those rings, they look quite professional. I bet you'd sell out fast if you made a batch.

Aw, now you got me thinking of how to make the jig to get the filing for the profile perfect every time, and how to build a sander table to clean them up easily!

I think I'll leave that to posplayr to make/sell these. It was his idea. That, and it would cost more for postage than what you would be able to charge for them. I may make up a batch if I find myself in a fiddly mood and end up making the jig and sander. Stranger things have happened when I am snowbound and bored!

 

[Turtleface]

So how did the forks turn out? Doing seals/paint/both?

Seem ok so far, fluid is in and not leaking, front end feels muuuuuch stiffer than the old bits. Right fork had 1/4 to 1/2 the normal amount of oil, left was at about 3/4. Stuff was thick, and the color of charcoal. Very much in need of changing. Smelt vaguely of fish. Pretty sure it was factory stuff. All the mechanical bits looked just fine, but I replaced all the wear items anyways, since I was in there. Actually took them apart, cleaned them, then rebuilt them with the old parts. Then I broke out the camera and did it all again. Too messy the first time to even think about touching sensitive electronics. I'll hopefully have the write-up done tonight or tomorrow night, depends on how much time I spend in the garage. No paint, I'm saving that for later, though the forks did get a good scrubbing. Cleaned up fairly nicely, some bare metal spots where the anti-dives had been leaking brake fluid, but not bad overall.

Funny, I was thinking that the throttle could use a bit more tension to increase consistency of control too. I don't think the tesion will change too much at the beginning of the twist since the profile is narrowest there, but I guess I will see. Almost seems "sloppy". I was also planning to sleeve the bar where the grip rides with teflon to make it as smooth as I can as well. Between the two, I think it shoud be much better.

I've got some of that DuPont Multi-Purpose stuff with Teflon. I have it in a spray and a squeeze bottle. Cleaned and lubed my clutch cable with it, and the action has never been smoother. The trick with this stuff is to make sure it's dry before you start operating whatever it is that's lubed. Used the squeeze bottle stuff on non-cable parts, like the pivot points for levers and shifter/brake, etc. Just get some on the parts you need lubed, and let it all dry before assembly. I've done all my cables with it, except the throttle cable, which I'm probably going to go do after I finish typing here.

 

[Macguyver]

Sounds like your forks received the same treatment mine did this summer past. I wanted to paint them, but it started raining just as I was trying to decide what paint to use, so I put them back on. I am wishing I would have painted them then.

I have a similar teflon spray, Tef-lube 2000 by kleenflow.
Who names these things? Really, Tef-lube 2000?
Works great though, rated for -34* to 315* C. It's the only thing I have found that really works on keeping my car locks from freezing. I treated the door seals by wiping it on with a cloth, and my car doors don't stick from freezing at all now.

 

[Macguyver]

Tail light update.

Tail light update.

As promised, here are the pics for my progress with the tail lights.

I went over to a friend's place and borrowed his woodshop for a half hour and shaped the delrin molding positive for my tail light shrouds, and cut out the center piece of delrin between the two holes in the ends. This gave me a nice, large open area in the center for the brake light lenses to fill.

I am going to smooth everything tomorrow if I can find the time, using a 1" flat file to level everything in the middle, and to put a finished surface on the outside bevels.

I also deepened the recess in the underside so the shroud will cover the lenses and sit flush with the rear fender lower I had made previously. I highlighted the areas in question in the image. I used a 3/8" 4 flute end mill in my drill press to remove the material very slowly, layer by layer until I had the depth I wanted.

*Great care should be taken if you must use an end mill in a drill press.*

The work piece can kick up if you do not hold the piece down firmly, I would always prefer to use a milling machine for doing stuff like this simply so the piece could be secured.

I think it turned out fairly well, all of the bevelled edge has the same angle now, and 5 minutes on the belt sander saved about 5 hours of hand sanding with a block. This delrin is tough stuff, no wonder they make frame sliders out of it.

 

[Macguyver]

More tail light pics

More tail light pics

Here are a few pics of the tail light shroud positive being held in place on my 650 for those who asked.

My main concern is that the tail lights are visible enough to traffic behind me. I may still play with the angles a bit, I am not sure yet. I will photoshop a few pics and see what looks best before I do any more cutting/sanding.

So far I like the look of it, it just needs that little something extra.

They shrouds will likely be either the same grey color as the lower, or a darker grey, maybe with some airbrushing, maybe flat black.
I will change my mind a dozen times between now and when the final part is ready anyway, so we'll see.

 

[Macguyver]

Salami cut?

Salami cut?

Photoshopped a salami cut in the shroud. This would not block any of the LED's in the tail lights to the traffic behind it, and look not to bad doing it, too.

Hmm, I like it.

 

[Macguyver]

Salami cut #2

Salami cut #2

Photochopped another one.

Maybe salami cut with mirrored louvres. Like tons of mini reflectors. I wonder if it would help disperse the light out more? If they were slightly angled to catch some of the light from the LED's and reflect it up and out behind the bike at specific angles, it might make the LED's visible from a wider viewing angle perhaps. :-k

 

[Macguyver]

Shacking Up.

Shacking Up.

I spent some time on the weekend clearing out the front entranceway at home so I could squeeze my 650G in there so I can actually work on it during the winter months.

I had to remove a very poorly constructed closet from the end of the entranceway, I didn't even need a hammer, a couple good palm hits took care of the fasteners holding the shelving, AND the supports. The thing fell apart like a deck of cards. It's a good thing I never really used it for anything aside from seasonal storage for snow shovels etc.

So now that I am "shacked up" with my bike, I can make some real progress on the customization. That, and it is much better for the bike going from sitting in the driveway with a cover on it, to inside, semi-heated storage.

It's a bit of a tight fit, but at least it fits. The only hiderance is going from one side of the bike to the other, but hey, I'll manage.