1981 gs450s

Larry D · Jul 21, 2014

Yes, that is exactly what I did with the caliper. It's all ready to go with the exception of the new pads, which should be in my mailbox soon. That task is a test of dexterity !!

I took a good look behind that bolt and didn't see any nut or any other captive device. It looks to be screwed in to the frame, but, I can't get it to loosen and I'm afraid I'm going to break it off.

Big Rich · Jul 22, 2014

If I recall correctly, that bolt is threaded into a solid point of the frame (not an individual nut).

Charlie G · Jul 22, 2014

Larry,

I have a set of black seat trim in good condition I'd send you for shipping. Now that you've repaired it.

cg

Larry D · Jul 22, 2014

Charlie G said:
Larry,

I have a set of black seat trim in good condition I'd send you for shipping. Now that you've repaired it.

cg

Thanks Charlie !!
PM sent.

Larry D · Jul 22, 2014

Look what I got in the mail today !!!

.....and it's time to start taking a better look at the electrics. It seems I'm going to need at least one coil.

Larry D · Jul 25, 2014

I thought I'd give a little update.

I got the front brakes all done and mounted, it is just finger tight awaiting a new bleeder valve, master cylinder and brake lever.

I got the battery box, tool holder (right side) painted. The electrical panel (left side) is next.

The coils have been removed because new ones are on the way. It's a longer story, but, I have two of these coming via ebay. Oh.....and a deep cleaning session is scheduled for this weekend.

Here was the problem with one of the coils. I tried to dig it out to re-attach another wire, but these particular coils are not designed to be re-used.

All in all, everything is moving along as planned. It will be time to start it up pretty soon.

Larry D · Jul 28, 2014

I had a big day in the garage over the weekend. First, my lovely assistant helped me clean and de-grease 33 years of grime.

Surprisingly my new master cylinder arrived early, so now, the front brakes are finger tight and fluid ready.

The valve cover has been removed. The cover bolts came out like butter, no issues. I still have to clean the gasket off though.

Some headlight inspection and cleaning was done.

My brother-in-law left this with me on a recent visit and it happens to fit perfectly into the mirror mount, it's not staying, but, it looks kinda cool for the minute.....LOL !!!

theresthatguy · Jul 28, 2014

Larry D said:
I had a big day in the garage over the weekend. First, my lovely assistant helped me clean and de-grease 33 years of grime.

What de-greaser did you use? and what was your method?

Larry D · Jul 28, 2014

Heck...I just bought some cheapo cleaner/de-greaser from the Dollar Store, nothing special. I have a bag of rags and went through plenty of them. Before the initial startup the bike will get a nice rinse down with some clean water to wash of any leftover residual cleaner.

My method ???? Get down and dirty and get scrubbing !!!

theresthatguy · Jul 28, 2014

Fair enough. I was just curious because I have a lot of grease on the front side of my engine this burns and smokes. I've read that de-greaser and power washing is a good way to get into all those fins and nooks but I don't have any way to trailer my bike to a car wash.

Larry D · Jul 28, 2014

I went behind a local supermarket and found the thickest cardboard I could find, it was a watermelon case, and laid it out on the garage floor. It did a fine job of keeping the garage floor clean. I actually kept it, it may come in handy later on....

Larry D · Jul 29, 2014

Yesterday was a huge parts day for 450S. First, the bodywork was completed. Thanks to Charlie and Brett !!!!

I also got the bolt kit from Z1. Here it is all separated out in an egg carton.

And finally, these two new sticky round rubber things.

There are still a few hurdles. A broken exhaust stud being at the top of the list. At least the re-assembly has begun !!!!

rustybronco · Jul 29, 2014

Larry, If you even need to install a caliper piston again, put the boot in its groove, lube the seal,bore and piston with brake fluid- place the caliper piston over the boot and lightly blow compressed air into the banjo bolt hole. The piston will seal off the boot so pressure can build expanding the boot enough to go around the piston. Then it a simple matter to rock and push the caliper piston into it's bore.

Larry D · Jul 29, 2014

rustybronco said:
Larry, If you even need to install a caliper piston again, put the boot in its groove, lube the seal,bore and piston with brake fluid- place the caliper piston over the boot and lightly blow compressed air into the banjo bolt hole. The piston will seal off the boot so pressure can build expanding the boot enough to go around the piston. Then it a simple matter to rock and push the caliper piston into it's bore.

I'll try that next time. Thanks.

Larry D · Jul 31, 2014

I didn't take a lot of pictures, but, to say the least, it was an exciting evening in the garage last night. A couple esteemed GSR members stopped by to help in the resurrection of the 450S. Alot was accomplished. Broken exhaust bolt is out, front brakes are braking, valves adjusted, new coils installed and 95% of the wiring is done. Not much more before I'm posting riding pictures !!!

I took a pic of the bike with all the body pieces, just to get an idea how it's going to look. It the first time I've had them all on there.

Brian tried his best to weld a nut on an offending broken exhaust bolt, but, it was just to stuck for even this method to work. Finally it had to be drilled out with a left-handed bit. Luckily, and due to Brian's skill with a drill, the threads were saved and a new exhaust bolt now sits in it's place.

Now....on to the entertainment for the evening....A kid, that lives about 8-10 houses down the street, was coming home and smashed into my truck that was parked on the street. I'm still sick to my stomach. Thankfully, no one was hurt. What an exciting evening !!!
These are pics from this morning.

Larry D · Aug 1, 2014

Last night, more significant progress was made thanks to the koolaid kid. 99% of the wiring was completed, the oil and filter was changed and the exhaust re-installed. At this point, I am a cam chain tensioner rebuild away from starting it up !!....Don't ask.....sometimes there are parts you forget to order....But, we have power and lights !!!!

Here's a look inside the oil filter housing. It was about the nastiest oil/gas combo I'd ever seen. Also, got to finally get rid of the drip pan since a new oil drain bolt gasket was installed.

As it sits.....with the reflection of the GK in the background.....

Larry D · Aug 4, 2014

Big Rich · Aug 5, 2014

Larry, look into some older posts by Mekanix dealing with the ignitor. You could probably get one from a GS500 and wire it into your system since they do basically the same thing between the two models. IIRC, a GS500's ignition advance kicks on about 1000 rpm later than the 450's.

The bike is coming along rather well btw!

jeffgs · Aug 5, 2014

Larry this has been an entertaining thread. thank you

Larry D · Aug 5, 2014

Thanks Big Rich, I'll look into it. Entertaining is an understatement jeffgs. LOL !!!

So, while I'm trying to figure out the next step in resolving the ignitor situation, I thought we should go ahead and get the tires mounted. I'm going over to Indy Suzuki West.....uhmmm......errrrr.......I mean bwringer's garage.....on Wednesday night to do some tire swapping. I have a standing appointment every Tuesday night, there will be no bike work tonight, so, I removed the wheels last night.

On most GS's you can remove the top or bottom mount for the shocks and drop the swing arm below the exhaust to gain access to the rear axle. The '81 GS450S will not allow this, due to the rear mounts for the exhaust interference with the swing arm. I ended up removing the bottom mount for the shocks (the top mount would've been better), placing a car jack under the rear tire and lifting the swing arm until the rear axle cleared the exhaust from the top. It wasn't to difficult, however, you must be careful with the balance of the bike. It gets a bit unstable and an additional person stabilizing the bike would help, but I got the job done.

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