Learning as I go, a log of my first bike

[donimo]

I just wanted to do a log of simple condensed points about issues with my bike and how they were solved. It might be helpful for other newbs, but mostly so I have a writted log of everything I did to this bike. I will add pictures as I go too. I will add in brackets where I got the information from, GSR, my uncle, Haynes manual etc. The "end game" would hopefully be my bike restored to glory, but we will see what happens.

First I will list the things I did BEFORE I ever rode it, not much point elucidating too much on them as I have no "before" to compare too.

Here is a pic "as delivered"



1) I replaced the tires with Cheng Shin Hi-max (GSR) front and back, the ones on the bike still had tons of tread, but had cracks along the side. Getting the wheels off with no jack etc was a pain and very precarious with wood and a car jack and a tie strap...

2) had the wheel off anyways so I replaced the rear brakes (Haynes), they were getting close and for $35 saves taking the wheel off again later. the cush looked good IMO, when I put the wheel on I set chain tension as well (Haynes)

3) full carb clean and o-ring replacement (GSR/Bikecliff), I ended up using OEM parts, one day I would like to find out if cycleorings kit would have fit...

4) Intake o-ring (GSR) while I had the carbs off, again used OEM, my bike uses a different size than the 450 so no go. Funny thing is I bought a top end kit that came with them anyways, ah well, spares.

5) replaced the chair foam homemade filter (Haynes) the PO put in, it had the tiniest cells in it, not sure if air actually went THROUGH or AROUND it... Used OEM part.

6) Did valve adjustment (GSR/Bikecliff/Haynes), this was a PITA due to 2 stripped adjusters, no gasket just the stikiest silicone EVER. After some help from a GREAT guy (Jetta90) I had my adjusters and set the valves. I have a feeling I set them too loose after reading more about feeler guages so they may be closer to 0.15 than 0.13, it IS a bit ticky but it runs fine? I made a gasket for the cam cover (GSR) from a roll of gasket material, that was fun that cover is not a simple shape!

So thats what I did before I rode it. Thanks to all on GSR for the help, now on to what I have done since:

[donimo]

Replaced Spark Plugs, the old ones were blaaaaaack, but the old air filter might have had a lot to do with that.

The new ones almost look a bit white, suggestions on GSR hint to the leaky exhaust being the culprit, solution forthcoming...

The left plug has oil on the upper threads, so oil must be leaking from up top, but its bone dry up there, ???

[donimo]

Lubed throttle, tach and clutch cable (haynes). WOW, big difference.

The throttle was rising when handlebars were turned to lock, that is now gone.

The clutch was hard to pull in and the engagement zone was TINY, seems a simple lube is all it needed.

Tach "hooted" before, now it does it when it is cold only, better but still not fixed, hmmm.

[donimo]

I replaced the controls with levers off ebay (Haynes), after reading these may not be the best quality, but my brake lever was busted (PO dropped in driveway) and they were $10 for the set. Much nicer having a whole brake lever to pull haa.

[donimo]

Adjusted the shift linkage (trial and error), still a bit sloppy, but I think the ball/socket connectors are loose and I dont know if they are supposed to be or what, no exp with those...

But I raised it a bit and it feels a LOT better.

Seems to shift better too but that me be in combo with lubing the clutch cable (did at same time)

[donimo]

Added some Cortech tourmaster saddlebags and tail bag, LOVE them, great storage and easy too mount.

Edit: I obviously sink the butt of this bike a LOT as I burned the strap in half on the way to work. I put it through above the wheel with a good 6"+ but obviously not enough, damn, now I need to buy/make new straps...

[BentRod]

the gs400 is a great bike, good to see your build is going smoother than mine did. And yes, it is hard to get OEM parts, as most dealers use American catalogs. Those catalogs only have the 450, because the americans never officially received the TSCC 400.

6 inches is a lot of movement. you may want to pull your rear shocks and check if they are sucking air. just remove them from the bike, and hold them upright on a plant of wood. Push down on the top with your hands to compress them a couple pf inches by bouncing. Listen for any loud sucking sounds to indicate air is moving in and out of the shock.

[donimo]

I bought new ones, they are teh MDI brand, which isn't great apparently, but they ARE cheap, and hopefully better than what I have, hope to have them on this weekend.

I agree, although it is my first bike and full of issues. I have wound it up a few times on "the long way" home I take now, ha, and it's plenty fast for me. But I have always thought it was more fun to run a small car/bike/whatever full nuts than to lope along in a high power beast you have to play nice in all the time

[BentRod]

There are a lot of nice roads out your way, and especially if you get off the island and go into the mountains.
I have cousins out west, in Vancouver, and on the 25th I'm headed out there to meet the newest addition to the family, (Sana, now 3 months old) and possibly go for a ride. my cousins have a 400seca and an RD350.

[SqDancerLynn1]

I bought new ones, they are teh MDI brand, which isn't great apparently, but they ARE cheap, and hopefully better than what I have, hope to have them on this weekend.

What you might want to do is press out the original shock bushings & reuse the metal insert- at least on the top mount

[donimo]

- I used some of that muffler patch kit stuff to try and seal the leak where the cans clamp on, no go it blew out in 5km and was waaaay louder than before.

- I took off the can and wrapped some of that sticky foil used to seal ducting (not duct tape) arount the pipe then clamped to that, it is as good as it was before the patch job fiasco at least, but still leaks.

- I can get the idle mix screw to work now, turning it did nothing with the big exhaust leak so there you go. AWESOME idle now, didnt know it was bad until it was good, ha.

- I also think some of my valve tick is actually the exhaust as it isnt as bad today after the partial fix.

[donimo]

- Installed the MDI brand shocks from Partsnmore.com, man what a difference just in the garage! The old ones would sink a good 6+ inches when I sat on the bike, MDI's about 1-2".

Test ride does confirm the "MDI's are really stiff" I have heard, but I am 250 on a good day so I don't mind it too much. Handling/stability is MUCH improved in corners and straights (straights was surprising, i am sure there is a reason though). Took about an hour, but only because I had to hunt for my book to find torque specs and I reused the bushings from the stockers which took time to press out.

_ Have a cold start issue with the clutch appearing to be wghat feels like 10-15% engaged with the handle fully pulled. I adjusted the pushrod clearance as per the manual ( 1/4-1/2 back from feeling it lightly seat), both ends of the cable and its still there. Thant being said the clutch does feel better now in all other areas. Have heard it may be due to the oild thickness when cold. Guess I will just start in neutral and let er warm up.

pix with new shocks forthcoming

[donimo]

- Installed MAC 2-1 system. Not sure if it was meant for the early model 450E's or something, but it took some finagling to get it on there, mostly brake pedal stuff...

was a pain to get the sound right too, muffler is not meant to be packed but sounds like ass if you dont. I used Stainless pot scrubbers and pipe insulation, seems ok now.

- Installed some brake pads off fleabay, Ferodo Platinum's?

Old pads had tons of pad left, but were really scratchy sounding and didnt stop well, for $14 for the ferodo's Ill just swap em...

stops much better, cleaned the brakes a bit and put new fluid in.

- Installed some Emgo (?) mirrors from jc whitney, cant see squat out any mirrors I have tried out (nice parts guy at local bike shop) so if I cant see I want the smallest ones you got, ha ha. I am 6'5" so all I see is my elbows...

[donimo]

- Installed new clutch cable, clutch was VERY "sticky" fine if you just let it out quickly, but if you went too slow it would stop and stick, every hil start was either rough as crap or a stall. New one ok so far...

gear selector may have been off a tooth, I installed it off one from where it was and it shifts MUCH better, hmm, darn PO's

- synched the carbs, getting a fuel line to the carb that didnt leak gas all over the bike was tough. Can't tell a lick of difference in the bike either. All that talk about how inportant it is from you guys and I can't even tell, ha ha, I know its good, if for nothing else than to tick it off the list.

Bike is running really well, still seems to have a bit of a flat spot in the power band at WOT around 4-5k, but I can live with it until I have more time to spend on it.

[donimo]

Quick video so you can hear what the Mac 2-1 sounds like with the SS pads and pipe insulation installed. Had to be quick as the neighbors were having a wedding reception and I hate our other neighbors for revving motors all day so...

http://www.youtube.com/watch?v=vKojKxi27_k