First Bike Build Ever (GS450)

[PhillyCafe]

Hey guys,

I'm new to the forum and the bike scene in general. I just picked up this bike on a whim and am starting to do some research on her. So far what I know is that it is a GS450 that had some modifications done by the previous owner like a new regulator/rectifier, straight through pipes, and the seat. My main question for everyone out there is where should I start? I want to get this bike cleaned up, stripped down and repainted. There's a bit of surface rust on the frame and I noticed that the wiring looks like a mess. She runs great and starts right up so that isn't an issue. Aesthetics wise I am still putting my head together on what to do but that won't be for awhile. Let me know what you guys think and I will be updating as I go on.

One thing I have ordered is a oil pan gasket that the previous owner told me should be done. So when that gets in I will look into tackling that.

 

[T8erbug]

Looks like a good start! I like the front end (fork gators and brake adapters). If I were you I'd get working on a new tail and seat. The exhaust could use some paint or wrapping. Wheels could probably be cleaned up. Lastly it looks like there are a few loose tabs on the frame that could be cut off and cleaned up at the same time as the rest of the frame. Other than that you might as well keep it cheap and just enjoy!

 

[GSXR7ED]

Welcome--nice bike! You'll be getting a welcome message with all the trimmings to assist you with everything you'll need to work on your bike. Keep us updated.



Ed

 

[koolaid_kid]

And a front fender. Despite the current trend, you really need that thing.

 

[Guest]

Hey mate, welcome!

Firstly, did you get that from a guy called Dennis? It looks really familiar to me and I'm pretty sure the guy's name is Dennis who I'm thinking of...

If it's the one, those are Salty Monk's adapters on the brake calipers to take the twinpot Kawasaki calipers.

That front end I think you'll find is from a 550 if I remember correctly.

Also, and again if I remember correctly, you will have some very nice but non standard carby's on there as well. I can't remember the model unfortunately or if they're Keihins or Mikunis, but they should be good.

On the negative side, no front guard really is a bad thing... it doesn't just keep the crud off if it gets wet but also acts as a fork brace to a certain extent, making the front end feel a lot more solid under braking and when cornering.

Personally I'd do something about some sort of muffler in the pipe as well. My 450's pipe is a custom that is pretty free flowing but it's plenty loud enough, and louder and it would actually be very uncomfortable to ride and these twins just don't sound good with open pipes... but that's just my take on it...

If this is the bike I'm thinking of, then I believe he has taken some time to get the jetting sorted, so if you do something with the pipe, you'll definitely need to re-jet as well otherwise it will start running too rich.

Anyway, good luck and keep us up to date with how it goes!

 

[Tim Tom]

PhillyCafe,

Nice looking cafe project you have there! It looks like the PO (who I think also was a member here at some point) did a lot of the footwork for you. Those are the Salty Monk brakes up front and Stainless Steel lines. All good there.

As for where you should take it? I'd start with a cut down front fender (you really do need one) and do something about covering that seat. A motorcycle seat should NEVER be white .

Spend the winter cleaning it up, and you will have a really nice bike when spring rolls around.

 

[PhillyCafe]

Thanks Pete,

Matter of fact it was owned by Dennis before me, it's interesting how some members can remember a bike so well. A few people have advised me to get a front guard so I will look into that and definitely want to clean up the pipes a bit. I'm going to look for original thread of my bike to get a better idea of what Dennis did before me so I get into it. I will be keeping this updated as I go but I'm taking my time, I need a license first lol.

Thanks the help!

Hey mate, welcome!

Firstly, did you get that from a guy called Dennis? It looks really familiar to me and I'm pretty sure the guy's name is Dennis who I'm thinking of...

If it's the one, those are Salty Monk's adapters on the brake calipers to take the twinpot Kawasaki calipers.

That front end I think you'll find is from a 550 if I remember correctly.

Also, and again if I remember correctly, you will have some very nice but non standard carby's on there as well. I can't remember the model unfortunately or if they're Keihins or Mikunis, but they should be good.

On the negative side, no front guard really is a bad thing... it doesn't just keep the crud off if it gets wet but also acts as a fork brace to a certain extent, making the front end feel a lot more solid under braking and when cornering.

Personally I'd do something about some sort of muffler in the pipe as well. My 450's pipe is a custom that is pretty free flowing but it's plenty loud enough, and louder and it would actually be very uncomfortable to ride and these twins just don't sound good with open pipes... but that's just my take on it...

If this is the bike I'm thinking of, then I believe he has taken some time to get the jetting sorted, so if you do something with the pipe, you'll definitely need to re-jet as well otherwise it will start running too rich.

Anyway, good luck and keep us up to date with how it goes!

 

[PhillyCafe]

Been thinking about a front fender and definitely a seat. The one that was on it flew off in transport so I've been using some extra padding I had lying around as a temp seat while I toy with it lol.

PhillyCafe,

Nice looking cafe project you have there! It looks like the PO (who I think also was a member here at some point) did a lot of the footwork for you. Those are the Salty Monk brakes up front and Stainless Steel lines. All good there.

As for where you should take it? I'd start with a cut down front fender (you really do need one) and do something about covering that seat. A motorcycle seat should NEVER be white .

Spend the winter cleaning it up, and you will have a really nice bike when spring rolls around.

 

[Tim Tom]

I need a license first lol.

Glad I wasn't the only one to buy a bike before having a license !

The VERY first thing you should do, before the seat or fender is get some good basic training. Sign up for an beginning rider course. You will learn the operation and handling skills of a motorcycle, but also lots of other things to help you be a better and safer street rider. There is no substitute for rider training and practice, best to learn right the first time so you don't develop bad habits.

http://www.pamsp.com/CourseInfo_Basic.aspx

 

[MAJikMARCer]

The VERY first thing you should do, before the seat or fender is get some good basic training. Sign up for an beginning rider course. You will learn the operation and handling skills of a motorcycle, but also lots of other things to help you be a better and safer street rider. There is no substitute for rider training and practice, best to learn right the first time so you don't develop bad habits.

http://www.pamsp.com/CourseInfo_Basic.aspx

The training course is a lot of fun too. Everyone else there is in a similar situation so it's pretty relaxed. No one in my class judged anyone else. Well the instructor did at the end, but it was their job to.

 

[Guest]

Ok, Dennis' screen name is "djg42" and he put Mikuni VM34's on there.

http://www.thegsresources.com/_forum/showthread.php?t=183266

That's definitely the bike, so it'll be good to know the history.

I don't recall there being an original build thread, I think there were individual threads here and there for issues but there still should be plenty of info for you.

 

[hjacobmiller]

PhillyCafe,

Nice looking cafe project you have there! It looks like the PO (who I think also was a member here at some point) did a lot of the footwork for you. Those are the Salty Monk brakes up front and Stainless Steel lines. All good there.

As for where you should take it? I'd start with a cut down front fender (you really do need one) and do something about covering that seat. A motorcycle seat should NEVER be white .

Spend the winter cleaning it up, and you will have a really nice bike when spring rolls around.

Aren't you the one who told me to put a white seat on mine....? Ha ha

 

[Tim Tom]

Aren't you the one who told me to put a white seat on mine....? Ha ha

SHHHH! That's only because it fit the classic 50's teal and white vibe of your build. As I didnt 'tell' you, more of proposed as an alternative. Along with a bunch of other options

 

[PhillyCafe]

Thanks for the support everyone and I will be updating as I go. I just started looking through the old threads from the previous owner of the bike and I am learning a lot, especially that there is a lot I need to fix. Once again, the wiring is going to be a huge debacle (I'll post pictures) and then I need to replace the oil pan gasket. Any tips?

 

[Tim Tom]

When doing the pan gasket take your time, clean all the old gasket off, but be sure not to nick the metal. Also the bolts have a specific corresponding thread, so keep them in order.

Be sure to get a real Suzuki gasket, many of the after market ones are garbage and will leak.

Also PB blaster is your friend, and be sure not to over torque them going back in. The old alloy strips out very easily. Use a torque wrench and the proper torque setting.

Finally, have fun doing it! Wrenching can be very enjoyable and satisfying, or a pain in the ass. Depends on your attitude and how well the job is going

 

[salty_monk]

I suspect those to be GS650 forks as the 550's had the mounts on one fork leg only.

Measure the diameter. If they are 35mm at silver end then they are 650 or 750 forks. If they are 37mm they are 850 or 1000 forks.

Rotors are Honda CBR, Calipers are Kawasaki Ninja or Concourse (probably Concourse as they are silver).

 

[Chuck78]

Welcome, & congratulations on your GS! I'd recommend measuring the forks & ordering a Tarozzi fork brace. They list 83 gs650gt in their catalog as a tested fit, 81-83 should be same. They could be gs750 forks as well...
Find out what Dennis put on there, & if they are stock springs, etc. Sonic springs & mikesXS cartridge emulators will be a top priority in upgrading mine soon, as well as a Tarozzi fork brace that connects the lower legs below the seals to stiffen it about 20x more than a fender does. A nicer set of Hagon $200-300 rear shocks will really help also. Cutting the factory fork springs down to 13-1/2 or 14" will improve the soft stock spring rate a lot also. Then you have to add a pvc pipe spacer to make up the difference.

If your mufflers are totally gutted, you can make your own straight thru baffle with some car exhaust tubing, drill press, & mig welder, & it wont affect performance or jetting much vs gutted shells.

 

[Chuck78]

Also, I think those type of mag wheels would look AWESOME in you sanded just the rim surface down with 300-400 grit sandpaper, & then spentsome time with a 4" buffing wheel on a handheld angle grinder polishing them to a mirror finish withmothers mag& aluminum polish or similar. Then sand the rest lightly, clean with wax & grease remover (autobody supply store), & spray the spokes& hub areas all hi-temp gloss black or gloss black appliance epoxy.

I saw some late model wheels done like that & they looked AWESOME! Best of luck, have fun & be safe!

 

[Guest]

That's sort of what I did with my wheels... I didn't mirror polish the lip though and I used POR 15 Blackcote for the paint... very happy with how they turned out

 

[PhillyCafe]

1 Step Forward, 2 Steps Back

1 Step Forward, 2 Steps Back

Hey guys thanks for all of the help on the forks and wheels! I forgot to measure them up when I was in the shop yesterday so I will do that and post my sizes.

Now, for what I did over the weekend... I decided to tackle the leak coming from the oil pan. I drained the oil and successfully removed the oil filter ( two 11mm nuts and one 10mm nut???) and cleaned that out, removed the bolts from the pan and removed that, and then removed any excess gasket (completely shot) that was stuck to the pan and underside of the engine. I fitted the new gasket onto the pan and secured it with some Three Bond and then reattached it to the engine.

Next is where I messed up.. When I went to put the new oil filter in and replace the cap, I had decided to replace the old and random sized nuts with new 10mm because they felt like they gripped the best. I tightened them up (so I thought) and filled the engine up with oil and went to run her.

Oh, how oil went everywhere!

Oil spewed from the cap and I cut the engine. I assumed I was just an idiot for not tightening the nuts up enough, so I went to take them off and put them back on. No go.

The nuts are now stuck to the stud bolts where the oil filter cap attaches and I cannot get them off, even with an impact gun (was careful).

I need to know where to go from here, idk if the stud bolts are bugged or if it was my dumb fault for not completely replacing the nuts with acorn nuts. If the studs are messed up how would I go about fixing them?

Any help would be great!

Go ahead and look through the album, it's got all the pictures of the bike so far.

http://www.facebook.com/media/set/?...1407990348223.537954.674248222&type=3&theater
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Also, I am putting up pictures of the speghetti mess that is the electric system so if anyone wants to give me an idea of where to start that would be great.

http://www.facebook.com/media/set/?...1407990348223.537954.674248222&type=3&theater

Thanks guys!