1981 GS450E Rebuild

Well, that's true Andre... but what will I ride while the stators out?

I gotta ride now you know

Well, at least you have all our sympathy! And the ride will be so much sweeter!

[pete]

Well you've been around here long enough to know you have to have a back up ride when you have a project on the go doncha?

Time you got a spare don't you think? Its just like another spanner/wrench in the toolbox Hopefully your "boss" is like mine and allows you a 2 bike limit (right now I'm cheating, I have 2.5, I figure if its still a basket case its a .5 not a whole one so I really don't have three....so far she's making an allowance for me)

Now get out there and find something to "tide you over".

Cheers mate,
Spyug

Hahahahaha I love your thinking Spyug!

Alas there are no funds for an additional one at present, and the next project is what I have already which will be the 50cc Ducati Cucciolo which is just a motor, nothing to put it in at present... I don't fancy that will be a good daily transport alternative

Thoughts of a 750 popup Katana still enter my head on regular occassions but there are no funds for such a beast at present and nowhere to put it... I barely have room for the 450 at the moment... I need to have a conversation about a two car carport out the front

Well, that's true Andre... but what will I ride while the stators out?

Well you've been around here long enough to know you have to have a back up ride when you have a project on the go doncha?

Time you got a spare don't you think? Its just like another spanner/wrench in the toolbox Hopefully your "boss" is like mine and allows you a 2 bike limit (right now I'm cheating, I have 2.5, I figure if its still a basket case its a .5 not a whole one so I really don't have three....so far she's making an allowance for me)

Now get out there and find something to "tide you over".

Cheers mate,
Spyug

[pete]

Bummer Bro... I am also worried about my stator. I am hoping it was just a fried R/R last time that was my electrical nightmare. We wont know till I get juice back into it. Hope you find the gremlin and it is only a loose wire.

Paul

Fingers crossed for you Paul, hopefully it is just the R/R...

Well Pete, that is one thing that MUST happen to all GS owners!
You can rewind yours for a fraction of the cost. Why would a GS owner just go out and BUY a new one, especially after such a comprehensive rebuild?

You are going to lose out on that job satisfaction, afterglow, thing!

Well, that's true Andre... but what will I ride while the stators out?

I gotta ride now you know

Well Pete, that is one thing that MUST happen to all GS owners!
You can rewind yours for a fraction of the cost. Why would a GS owner just go out and BUY a new one, especially after such a comprehensive rebuild?

You are going to lose out on that job satisfaction, afterglow, thing!

Bummer Bro... I am also worried about my stator. I am hoping it was just a fried R/R last time that was my electrical nightmare. We wont know till I get juice back into it. Hope you find the gremlin and it is only a loose wire.

Paul

[pete]

Gaaaaaaaaaaaah... went to head to work this morning and she wouldn't crank... wanted to but wouldn't... grabbed the mulimeter and battery says 13.5v... bugger! Trained it...

Anyway, got 5 minutes to have a quick look this avo and the acid level is good (one thing I forgot to check in the first service) and after a short time on the charger I was able to get her to fire.

With rev's DC voltage maxes out between 12.2 and 12.5v

Only had time to check one leg of the stator and rev'ing the ring out of her in the garage yielded about 50VAC

I need to check the other two legs and the first again when I have more time to confirm but looks like a new stator is in order dammit...

At least she's putting out enough juice I can trickle charge her overnight and keep riding until I can get a stator.

Local mob www.motorcycle-parts.com.au carry Electrex stators and looks like retail is $115.50 which should be doable after pay day next week I hope. Research here shows it should be a good product.

[pete]

Do you ever get the idea that Pete is just dragging this thread out so that he can have the longest running thread in the GSR?

I must just saying is all.

Paul

Took the words out of my mouth. I haven't followed this thread for awhile and when I looked today I noticed the count and that's exactly went through my mind.....I **** you not. But its ok because he does good work and its very entertaining . Just what we need right now with this crazy weather. Can't ride yet so we need something to keep us "tuned up". Thanks Pete !

Cheers all,
Spyug

Hahahahaha now c'mon fellas

Actually the length of the thread hasn't escaped my attention... but you may have noticed I've never said she's actually done yet... there is definitely more I want to do to complete the project... it's just taking longer now coz I get to ride her

And cheers Spyug, it's not all good but some of it turns out ok Glad I keep you amused during your snowy season

As for the tool tray, well I'm probably not getting back to that until Sunday or Monday night at the earliest. Few beers tonight and tomorrow is wash and polish in preparation for the run on Sunday... can't wait for Sunday actually!

Do you ever get the idea that Pete is just dragging this thread out so that he can have the longest running thread in the GSR?

I must just saying is all.

Took the words out of my mouth. I haven't followed this thread for awhile and when I looked today I noticed the count and that's exactly went through my mind.....I **** you not. But its ok because he does good work and its very entertaining . Just what we need right now with this crazy weather. Can't ride yet so we need something to keep us "tuned up". Thanks Pete !

Cheers all,
Spyug

Do you ever get the idea that Pete is just dragging this thread out so that he can have the longest running thread in the GSR?

I must just saying is all.

Paul

[pete]

Looks great Pete. I know it can be aggravating when it's almost there but not quite. Hope you sort it out soon and it does what you want.

I started thinking of a different way to mount my electrics but am hesitant to start it as I'm not sure about where to put it or if the idea would even be smart. I'll probably leave them where they are on the air box for now but I'll follow your ideas here with interest.

Cheers Scott, I'll be stoked when I get it in there and have somewhere to put my tools and things without need to lug the tank bag everywhere!

Moving the electrics is reasonably straight forward and because I didn't end up moving my battery, the only wiring I had to touch and customise were the runs to the main fuse and starter solenoid and running extras for the single point ground etc.

[cowboyup3371]

Looks great Pete. I know it can be aggravating when it's almost there but not quite. Hope you sort it out soon and it does what you want.

I started thinking of a different way to mount my electrics but am hesitant to start it as I'm not sure about where to put it or if the idea would even be smart. I'll probably leave them where they are on the air box for now but I'll follow your ideas here with interest.

[pete]

Ok this is getting frustrating... it's so close!

Cut off the end of the front mounts and bent the front up so it's a tray all 'round now:



And this is the rubber I have that I'll be glueing on there as a bit of cushioning:



So I can now get the one side in sort of but my measurements are out as I think I measured too low down, meaning it needs to be shorter:



So I trimmed the front which now lets it sit in almost like it should, but it seems the height of the side is now too tall and it's actually holding it too far forward and too much towards the centre so it doesn't line up with the tail light mounting bolt:



So I've left it there for tonight but I think I know how to finish it off now which means the other half will be much easier, then it's a matter of filing all the jagged edges smooth, glueing the rubber on, and getting it mounted.

Don't think I'll get it done in time for the run on Sunday but hopefully I can at least have it the right shape...

[pete]

Nice work. Looks great.

Well... I reckon it'd look better if I got it to fit

Maybe a bigger hammer would have helped you out a bit......

nice work so far

hope you get it in there.....

Haha yes indeed! I'll get it in there... I swear...

It looked so good, why did you cut it?
A little tweeking here and there and it would have been a perfect fit!
Am I missing something in the photo's?

Daniel

I know Daniel, I didn't want to cut it, but my mind screamed at me to cut it... with the thought if I fold it in half, it would fit. What the photos don't show is that without taking the tail piece, tail light, and rear guard off, there's no way it will go in that opening and be able to be maneuvered into place.

Once I sort the front out and stick the rubber over it, you won't see it's been cut but I'll have a hinge of sorts in the middle I can use to get it through the opening... stay tuned and I hope you'll see success soon

It looked so good, why did you cut it?
A little tweeking here and there and it would have been a perfect fit!
Am I missing something in the photo's?

Daniel