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1982 GS450L Rebuild/Mod

  • Thread starter Thread starter GregNC
  • Start date Start date
G

GregNC

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I got the bike from a marine who had bought it from the original owner. The bike was the marines first and he put about 7,000 miles on it bringing the total miles to about 14,000. About a year ago the marine was riding and he heard a loud pop and started leaking oil. He had a friend tell him it was the piston and would be super expensive to fix. So he ended up getting a new bike and let this one sit for a year. I was working on a friends short film next door one day and met the owner, chatted for a bit, and he tells me that I can have the bike if I could get it out of his place. So he signs the title over to me on the spot and I throw it in the back of our equipment truck. Cosmetic wise the bike was in pretty good shape no real rust on anything except the exhaust. I put a new battery in, new oil, new gas. It started right up. I have no real knowledge of motorcycle maintenance (this is my first bike) but I grew up riding dirt bikes and working on my own car. Back to the bike though, it ran up to about 50 mph and the tach was almost non responsive. I pulled the plugs and the one on the clutch side was covered in oil. A few days later a friend of mine that works on bikes took the top off the motor while I was out of town, he said there was a hole in the head of the clutch side piston big enough to put a pencil through.

So I set up shop in my new place the last couple days and turned a old unfinished laundry room and the space under the house that leads to it into my own little workshop. I'll post some pics today or tomorrow if I can get to it. My plan is to (sorry gs purist out there) modify the bike by lowering the rear end, chopping the rear fender a bit, dishing the tank, straight pipes (baffled) two tone paint job Black and Gun Metal. I've got a few pics of the look I'm going for I need to re-size and I'll throw them up here for you guys. I've attached a pic of what it looked like when I got it.

Since then I have removed everything. It's just a naked frame now and a pile of organized parts. The frames got a little rust in some spots as well as in the battery tray. I'm thinking I'll get it blasted and re-paint it black. Then slowly (still paying back student loans) I'm going to replace all the necessary parts for what I want and sell or discard my excess. Everything that was on the completely stock bike is in good order except for the handle bar starter/kill switch. It starts no matter what position it's in.



This is what it looked like when I got it:

http://www.thegsresources.com/_forum/showthread.php?t=183153http://www.thegsresources.com/_forum/attachment.php?attachmentid=14699&d=1317674243

More pics to come later today of the tear down progress!
 
Ok guys, I've had a rough time getting some pics to you but here they are finally.

This is how I got the bike, completely stock with a rattle can paint job. (the signals, brake light, rear fender and mirrors were included in some saddle bags)

http://www.thegsresources.com/_forum/album.php?albumid=1687&pictureid=9001
picture.php




Then I stripped her down

http://www.thegsresources.com/_forum/album.php?albumid=1687&pictureid=9037
picture.php


picture.php



The Keeper Pile

picture.php



Most of this will be sold or trashed (except the wiring harness) Basically just cables, gauges, muffler tip, stock seat, horn, also not pictured but included in this pile are the turn signals and brake light/license plate bracket. I'm also gonna put smaller shocks on so those stock ones will be sold as well.

picture.php


My makeshift workshop/man cave. It was an unfinished laundry room under our house here at the beach (the room in the back of photo). Took some old doors and saw horses and made a work bench. It's got power to run my mp3 player and light already hooked up. The best part though is that the air return from the dryer in the house runs into this little workshop of mine. Which will be great for this winter!

picture.php



So this is where I'm at so far. I guess my next step will be to sand and re-paint the frame and clean up the 30 year gunk that was covering everything else pulled off.

An interesting side note, I found the manufacture info on the frame and this bike (82 gs450L) was actually made in November of 81. So she'll be turning 30 next month. Nothing seems more fitting to me than to give her a good complete rebuild to celebrate the occasion.

More to come soon guys, I'll keep ya posted!
 
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Good stuff Greg, glad to see you getting some things done :)

Your bike's one month younger than mine, mine's 10/81.

I was hoping to have her done for her 30th birthday but I don't think I'm quite going to make it.

I should have some new clothes for her at least...
 
Progress Report: I've been working a lot lately. Which is good for my wallet, but it's killing my wrench time. I've got all the parts that will be put back on the bike all cleaned up. (shocks, wheels, handle switches, triple clamp, battery tray) I've got the frame and swing arm all sanded down and hit it with a coat of primer. I'll do another coat and then hit it with a high gloss black and some clear coat. From there I'll put together a rolling frame and get to work on taking off what I don't need on my wiring harness. Pics coming soon!
 
Good stuff, can't wait to see! I just got done with my paint job today aside from the polishing...
 
Progress Report: Got a few coats of satin black on the frame and swing arm. In the middle of cleaning up the wheels and shocks/forks right now. Hopefully I'll have a roller in the next few days.



Quick question for you guys. How many coats of paint should I put on the frame/swing arm? Right now they have received one light coat and one thick coat. Also, I'm looking to drop the rear end about an inch or two. I've heard suzuki savage shocks bolt right up and are about 10.5" instead of my stock 12.whatever" Only problem is I cant find any cheap ones online. With my student loans kicking in I can't aford to drop 150$ on some. I was also thinking that if I cant find any shorter shocks for cheap I could maybe modify my stock ones? cut the spring and shorten the shaft? What do you guys think?
 
Progress Report: Got a few coats of satin black on the frame and swing arm. In the middle of cleaning up the wheels and shocks/forks right now. Hopefully I'll have a roller in the next few days.

Quick question for you guys. How many coats of paint should I put on the frame/swing arm? Right now they have received one light coat and one thick coat. Also, I'm looking to drop the rear end about an inch or two. I've heard suzuki savage shocks bolt right up and are about 10.5" instead of my stock 12.whatever" Only problem is I cant find any cheap ones online. With my student loans kicking in I can't aford to drop 150$ on some. I was also thinking that if I cant find any shorter shocks for cheap I could maybe modify my stock ones? cut the spring and shorten the shaft? What do you guys think?

Cool, although we need to see pic's :D

Can't comment on your shock question as I just replaced mine with Ikons, but as to paint, it really depends on what you're using.

I did mine with POR 15 Blackcote and it says 2 coats, so that's what I did and I think it turned out pretty well considering I was brushing it on.
 
I'm using satin rustoleum rattle can metal paint. I just got done putting a 3rd coat on. Pics up later this afternoon!
 
Oh and before I forget, I checked Robert Barrs website for the 450 carb kit everyone recommends and it says that it's not available. Ideas? Can I order everything in the kit separate?
 
Good stuff on the paint. The POR 15 Blackcote is quite a thick self levelling paint so two coats is fine. If you're spraying, then yeah you definitely want enough coats for good coverage. I'm no expert at spraying though, just look at my paint thread ;)

Robert Barr posted a little while ago that he was having trouble locating suitable O rings for the mixture screws, which is why they're currently unavailable.

I'd shoot him an email to see if he has found a new source yet or if he's at least able to send you the other ones.

If you need to get some elsewhere, make sure they're designed for use with fuel.
 
Well I got a wicked cold the past couple days and have been basically bed ridden, pounding cold medicine and watching movies on my laptop. So no real progress on the bike. I did get the wheels all cleaned up. The frame has 3 coats of rattle can satin black. As does the swing arm, triple tree and engine mount tabs. I ordered the 450 carb combo from cycleorings. Thanks Rob. You rock. After this cold passes I'm planning on doing another coat or 2 of paint and then putting together my roller frame and scouting for savage shocks or something that's around 11'' to 10'' to drop my rear end a little. I'll throw some pics of the repainted parts up as soon as I can. I plan on finishing up this bike by my 25th birthday on March 26th. So bear with me, we got a little ways to go. With my low budget I'll do my best to keep rocking on this and keep you guys up to date as well. I havent come up with a name for the bike yet but I'm leaning towards stella. Has a classic hottie ring to it I think. Cheers from the beaches of North Carolina! and thanks for all the support!
 
Well I got a wicked cold the past couple days and have been basically bed ridden, pounding cold medicine and watching movies on my laptop. So no real progress on the bike. I did get the wheels all cleaned up. The frame has 3 coats of rattle can satin black. As does the swing arm, triple tree and engine mount tabs. I ordered the 450 carb combo from cycleorings. Thanks Rob. You rock. After this cold passes I'm planning on doing another coat or 2 of paint and then putting together my roller frame and scouting for savage shocks or something that's around 11'' to 10'' to drop my rear end a little. I'll throw some pics of the repainted parts up as soon as I can. I plan on finishing up this bike by my 25th birthday on March 26th. So bear with me, we got a little ways to go. With my low budget I'll do my best to keep rocking on this and keep you guys up to date as well. I havent come up with a name for the bike yet but I'm leaning towards stella. Has a classic hottie ring to it I think. Cheers from the beaches of North Carolina! and thanks for all the support!

Mate that's a bit of a bugger on the cold! Glad you got at least something done on the bike though, helps when you can at least knock off some little stuff.

How realistic do you reckon that timeframe is for completion? The only reason I ask is that I initially said Christmas last year... well it's nearly Christmas this year now! Would be great to go for a blast on your birthday though :D
 
I think that if I stay on my current work schedule and keep putting aside a bit of cash each week she'll definitely be ready to ride by march. Maybe not completely finished, but able to go for a spin. The engine is being professionally rebuilt by a custom bike shop here in town. I'll have that back before the end of november. All that's left for me to do right now is finish painting up my remaining parts I have already and start ordering new ones to throw back on here.

So far my list of new parts needed: Mini speedo, mini tach, headlight brackets, clutch cable, speedo cable, tach cable, front brake cable, turn signals, brakelight, starter button, killswitch, clutch spring, SS brake lines, grips, mirrors, gaiters. I'm also taking the stock seat, trimming the pan and foam and getting it reupholstered.

If I go a little past march on the rebuild it's ok but I definitely want to be done by summer. It's all just a matter of how much cash I can put aside for these new parts. Little by little we'll get there though. It helps having christmas and my birthday coming up. Great excuse to get some new parts from friends and family!
 
Cool, that sounds doable :)

Try MikesXS for some of those parts you're looking for too, they have a good range of stuff.

Oh, and Chrissy presents are definitely a good way to get stuff, just send 'em all a list to choose from ;)
 
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