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1981 GS450E Rebuild

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    Ok I did end up doing a bit tonight after all. I just concentrated on getting the alternator cover on as that's a bit of a quick win.

    So, finished cleaning the gasket remnants off:



    Some of my trusty threebond around each crank case seam as directed:



    Locating pin in and gasket on, and it should be nicely lined up with the oil gallery:



    And alternator cover in place ready to bolt on:



    It's actually a bit of a challenge getting the cover on without disturbing the gasket as the gasket needs to stay lined up with the oil gallery and the stator has a tendency to get attracted to the magnets which makes it a little tricky.

    And bolted on with my nice shiny new allen head stainless steel bolts from Z1 and with anti sieze on the threads:



    I also gave it a quick once over with the polishing cloth to try to get rid of my greasy finger prints too (still too clean Charlie ).

    And that's pretty much it for tonight, although I did start working a bit more on the gasket remnants on the right cover as that's the next one to go on.

    And I just had a thought... my closest dealer is in Windsor which is a flood risk suburb... man I hope they don't go under and I hope my parts are able to make it safely there for Saturday! Would be a real shame if I get time to work on it and they're not there...
    Last edited by pete; 01-11-2011, 08:27 AM. Reason: Typo
    1982 GS450E - The Wee Beastie
    1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

    sigpic

    450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

    Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

    Comment


      Energex eh?
      Small world, kind of.
      I used to drive for O.D. and deliver the big Wilson transformers across the country.

      That motor is coming together nicely now, looks sweet.

      Oh, I finished my weekend fridge "rebuild"

      Comment


        Originally posted by Leigh View Post
        Energex eh?
        Small world, kind of.
        I used to drive for O.D. and deliver the big Wilson transformers across the country.

        That motor is coming together nicely now, looks sweet.

        Oh, I finished my weekend fridge "rebuild"
        OD? That sounds familiar but I can't put my finger on it... and yeah those transformers are rather largish. There's a substation in the basement of the building I work in because we're such a power hungry business, and it ain't no small beast... will be interesting if that fills with water today or tomorrow!

        And cheers, I'm really happy with how it's looking. The polished covers and blasted cylinders/head should be a nice contrast to the cases. It's a pity my paint job is such crap, but the shiny bits should take the eye away from that

        I like your fridge! Job well done
        1982 GS450E - The Wee Beastie
        1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

        sigpic

        450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

        Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

        Comment


          Originally posted by pete View Post
          There's a substation in the basement of the building I work in because we're such a power hungry business, and it ain't no small beast...


          Well Hey Pete, this is one of the BIG MUTHA's that I look after during my spare time at work. V16 and check out the twin turbo chargers on top. It pumps out 2.5 megawatts when she fires up. And when you hit that air start you want to make sure you've got the doors open and ear muffs on.











          .

          Comment


            That's a serious piece of machinery Don!

            I haven't seen the generators at work so I don't know what they pump out or anything or how big they are, but I would imagine they wouldn't be small...
            1982 GS450E - The Wee Beastie
            1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

            sigpic

            450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

            Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

            Comment


              Pete I should have had someone stand next to the generator to give some perspective as to it's size. But as a hint the dipstick is three feet long.

              Comment


                That's one long dipstick! That take a great big drum of oil I would imagine...
                1982 GS450E - The Wee Beastie
                1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                sigpic

                450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                Comment


                  Hey hey! Less generator, more bike!

                  Well, after my little photo at least..

                  Comment


                    Are you trying to imply that size does matter?

                    I was hoping I couldn't connect into work today so I could get the egine in the frame, but alas the VPN works so there went that idea... oh well...
                    1982 GS450E - The Wee Beastie
                    1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                    sigpic

                    450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                    Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                    Comment


                      Right, sick of water and floods and hearing about them, so back to bikes tonight, got some more done. Apologies if anyone sees this who is actually getting hit by water as I don't mean to be insensitive, but I've just had flood overload from the telly.

                      Anyways... finally happy I got enough gasket crap off the right cover, I swear that was glued on:



                      Locating pins cleaned up and in:



                      Quick double check everything is in order and ready:



                      Gasket on with a bit of oil on the lip of the oil seal:



                      And in place ready to bolt up with new stainless allen bolts:



                      And anti sieze on the bolts and all done up nice and tight:



                      Next, advance governor all cleaned up ready to go:



                      And on with some thread locker:

                      1982 GS450E - The Wee Beastie
                      1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                      sigpic

                      450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                      Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                      Comment


                        Cleaned up the dipstick and inspection bolt and in they went:



                        And this is how she looks, and yes Charlie, I did give it another once over with Mothers so it's still too clean



                        So, 100% definitely ready for the frame, time to move on in the meantime and start cleaning up the harness and getting the camshafts cleaned up ready etc.
                        1982 GS450E - The Wee Beastie
                        1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                        sigpic

                        450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                        Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                        Comment


                          Originally posted by pete View Post

                          That is such a great photo..
                          It has me thinking things I should do..
                          Hmm, the kids don't need to eat as much as they do, really.
                          Surely they don't need both kidneys each...

                          Comment


                            Originally posted by Leigh View Post
                            That is such a great photo..
                            It has me thinking things I should do..
                            Hmm, the kids don't need to eat as much as they do, really.
                            Surely they don't need both kidneys each...
                            Haha cheers Leigh, but it does actually photograph better than it really is. That right cover is still quite cloudy, definitely not a mirror shine!

                            But you're right, kids eat way too much from what I've heard, and we have two kidney's for redundancy and there are plenty of people who've lost/donated one and are still fine

                            Now while I really can't comment on how your motor looks (still have seen no pic's yet), you should be able to get a pretty good shine going with it still in the frame, especially on the case covers.

                            My question is still about the oil filter cover as there's no easy way to polish it and I'm starting to think I should have sent it to be blasted with the cylinders and head...
                            1982 GS450E - The Wee Beastie
                            1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                            sigpic

                            450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                            Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                            Comment


                              Originally posted by pete View Post
                              My question is still about the oil filter cover as there's no easy way to polish it and I'm starting to think I should have sent it to be blasted with the cylinders and head...
                              Pete what do you mean there is no way to polish the oil filter cover. If you really cant polish it then just paint it the same colour as the crankcases, it will just blend in and not be noticed.

                              Comment


                                Originally posted by Suzuki_Don View Post
                                Pete what do you mean there is no way to polish the oil filter cover. If you really cant polish it then just paint it the same colour as the crankcases, it will just blend in and not be noticed.
                                I should've clarified Don... if I really wanted to, I'm sure I could give it a polish, but there are so many grooves and lumps and bumps on it that it will take hours to do.

                                I may paint it yet as I still have plenty of the Black Velvet left... plenty of time to decide though as I don't really need it on until I'm about to fire it up and am ready to put the oil in.
                                1982 GS450E - The Wee Beastie
                                1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                                sigpic

                                450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                                Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                                Comment

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