My 1981 GS650G Thread

[AF_Bill]

BTW Mac, I'll have the pics of the tank bag flak vest up later tonight. I wanted to ask you where I can pick up the electrical box you used to hide the wireing behind the headlight? I got a new custom light for my 650 and wanna clean up that nest-o-wires.

[Macguyver]

BTW Mac, I'll have the pics of the tank bag flak vest up later tonight. I wanted to ask you where I can pick up the electrical box you used to hide the wireing behind the headlight? I got a new custom light for my 650 and wanna clean up that nest-o-wires.

It's from radioshack, picked it up years ago.It is called a large project box. You should be able to find something similar at any shop that carries electronics.

I also seriously concidered using an PVC electrical box, but it was more convenient for me to use the project box since I wouldn't have to black it out. I am sure a resourceful man like yourself will get all sorts of ideas looking through the local depot electrical isle.

Post some pics of what you pick up, or if you have more ?'s, let me know and I will help out as much as I can.

[AF_Bill]

Thanks Mac. BTW, here's a pic of my Flak vest tank bag.

[AF_Bill]

On the tank.

[Macguyver]

On the tank.

Very cool,
Is it held on with magnets? Or are there straps?

I have to wonder how people many build their own tank bag? I know most people would rather just spend for one, but to me, there's no style, and you need to customize what you take, by what fits in the bag. Meh, I dunno, I myself prefer to make the bag to fit my needs. I guess I am kinda wierd like that though.

Once again, great work Bill, keep it up!

[AF_Bill]

It's held on by 6 2inX1in magnets and 4 small magnets on the snap straps. If I can get my hands on another one, I'll let ya know. I DO have some ABU/ACU material still from a flak vest layin around. I can send ya pics if you're interested.

[Macguyver]

It's held on by 6 2inX1in magnets and 4 small magnets on the snap straps. If I can get my hands on another one, I'll let ya know. I DO have some ABU/ACU material still from a flak vest layin around. I can send ya pics if you're interested.

Wow, I don't think your tank bag is going anywhere with those magnets in there!

I'll take a pass on the material since I still have a BUNCH of various camo material left over from othere projects, thanks for the offer though!

So I went out and started working on the bike again, only to discover that I am only getting 10.6 volts on the switched 12V line. Grrr. Looks like I am going to be rewiring the run switch and ignition sooner than I wanted.

I have finally received a reasonable insurance quote! 800 samoleons, then it will drop to $500 after I have been insured with them for a year. Much better than the $1100 a year I was getting quoted before. I guess I have the government to thank for changing the regulations regarding vehicle insurance. Unfortunately most of the difference is made up for by my car insurance going up $200 a year.

Who knew two-wheeled freedom would cost so much?

Anywho, one of my good friends will be getting his new (to him) BMW 900 soon, so I really need to get going on my bike so I can begin the year by riding down to his place to check out his new bike, then ride his old bike back up to my place so I can do some mechanical work on it before flipping it. Anyone interested in a 1982 Yamaha Maxim 400? I know you all want it, it's real purdy like! The tins are painted with PPG Vibrance Rattlesnake color-shift paint. Goes from a deep crimson to bronze to green, very snazzy.

Well, back to the bike I guess, I'll post progress pics once I get my low voltage situation fixed.

[tkent02]

Who knew two-wheeled freedom would cost so much?

It doesn't. It's your government that's expensive.

[Macguyver]

It doesn't. It's your government that's expensive.

I hear that!
Now we're having a useless election which will cost at least 300 Million taxpayers dollars, only to go from a minority government, to another minority government. I know I am casting my vote on monday, as will other responsible citizens, but it gets to a point where enough is enough. If they actually put as much effort into the running of the country as they do into slinging mud, then maybe we would get somewhere.

[Macguyver]

Start Switch Relocation and some good news!

Well, here I am again, solving the little nagging problems incurred by owning a "vintage" motorcycle. This time I needed to solve a rather alarming voltage drop.

The time had come to move the Run and Start switches from the right hand controls to the center console, so out came the electrical kit.

I decided to fill in the empty hole in the steering stem by filling it with the 12V lighted switch I picked up oh so long ago from ebay. I used the empty channel through the steering stem which was previously occupied by the choke cable, to run my wires from the switch.

I had to come up with some way to hold the switch in place since it was too large of a diameter to fit into the wiring channel, so I went on a hunt through my miscellaneous project supplies box, and came out with a lens cavity from an old Maglight which had given up the ghost.



This piece fits the bill nicely since it reduces the diameter of the steering stem down to the diameter of the round start switch, and adds that hint 'o red I was looking for to set the ignition switch apart.



The next step was armoring the wiring with some split loom, running the wires, and connecting in the aircraft style Run switch I had previously mounted on the center console.

Wiring in the new switches eliminated my nasty voltage drop problem, and gives me a neat looking addition to my machine. Now I just need to get rid of the bulky right hand control box on the handlebar.

Here's a video of the final testing for those interested.

http://img13.imageshack.us/i/wxn.mp4/

I also found the time to finally get the ownership for my bike transferred into my name. I know, I know, I should have done that right off the hop instead of waiting so long and putting all the effort into the bike to get it to this point.

Funny thing, the MTO (Ministry of Transportation of Ontario for you 'Mercians) couldn't find the VIN number on file. Luckily I had the old licence plate so they could backtrace it to get it. Apparently when the bike was first registered, the 2nd "G" in the VIN was mistaken for a "6" by whoever did the job. This very effectively renders the VIN on the steering stem incorrect according to the MTO.

Long story short(er), after spending a good chunk of the day waiting at the MTO, and running home to get the plate, then waiting in line again, I now have a valid ownership in my name, and there was much rejoicing. (yay!)

I faxed over the required documents to my insurance company today, ordered a new battery to replace my toasted one (which they would not warranty ), and have a safety inspection sheduled for early next week. So if all goes well, by this time next week, I will be on two wheels for the duration. Which is all the better since gas prices have gone up 15 cents a litre (about 60 cents a gallon) in the last three months, with no signs of stopping anytime soon.

I will post another update soon!

[Macguyver]

I hate helicoils/helicoil replacement

Almost forgot, as I was working on the bike the other day, I went to check my exhaust bolts at the header to make sure they were snug. Well one of the helicoils I had replaced earlier was rotating loose. Upon closer inspection, I discovered that what I thought was aluminum, was some sort of high temp repair putty!

I should really have noticed this before when I swapped out the SAE ones for metrics. So I ended up digging out all of the putty and found the P.O. had simply drilled a shockingly large hole, filled it with putty, and jammed the helicoil in.

So I was faced with the decision of taking out the engine to take it to a shop to get the gaping hole filled and retapped, or taking a different tack.

Guess which way I jumped?

You got it, I decided to tap the hole with an M12x1.75 tap, then grabbed a chrome M8 cap nut, reduced the O.D. to the proper size to run an M12x1.75 die down it to create a sizing adapter.







There we have it, the bolt is now snug as a bug in a rug, well, a bug with a liberal coating of anti-sieze that is! No more leaking exhaust problem, and I know the adapter I put in there will be very secure with about 6 turns holding it in place. Just for good measure, I also put a drop of sleeve locking compound on the threads before I tightened it in.

I feel better having the adapter in there as opposed to a helicoil, and I know if I have another helicoil come loose, I may just do the same again.

[pete]

Nice work Mac! Gonna be great to see you get it on the road at long last

[Macguyver]

Nice work Mac! Gonna be great to see you get it on the road at long last

Yeah, I can't wait!

I received my temporary insurance slip today, and my new battery will be in either on Saturday or Monday. Just a little while longer, but I don't mind waiting since it's raining cats, dogs, and even the occaisional squirrel outside right now.

Once I get her safetied, my first stop will be the car wash to give her a good pressure washing, then pics pics pics. Expect a new avatar and tagline image update very soon, and of course, some driveway shots, locale shots, hell, maybe even some model shots if I can find some willing PYT.

[recycled64]

Just about all of your build is amazing, but that exhaust fix is ingenious! It's the kind of thing, and I'm sure it's happened to you, that you sort of dream up, literally, just as you're going to sleep! So satisfying when it works out as you have envisioned it!

[Macguyver]

Just about all of your build is amazing, but that exhaust fix is ingenious! It's the kind of thing, and I'm sure it's happened to you, that you sort of dream up, literally, just as you're going to sleep! So satisfying when it works out as you have envisioned it!

Exactly, some nights I can't get to sleep for hours because my mind is too busy with ideas.

I stopped in at the suppy store and my battery isn't in yet. Waiting a few more days won't kill me...but it doesn't make the waiting any easier.