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1981 GS450E Rebuild

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    Originally posted by davidduarte View Post
    where did you order the repro manual from? I'd love to get a copy of that.
    eBay of course



    That's the one I bought, the seller says if he hasn't got one listed, contact him and he'll get one listed.
    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


      I finished up my temporary starter solenoid bracket tonight which is just to hold the solenoid and ground it for cranking until I get my spark issue and electrics tray sorted.



      I did give it a quick flick of the starter switch tonight and it cranked

      I have yet to get some different oil to put in for the first start (going with Castrol GTX Diesel 15w40) so I didn't give it a proper cranking or anything.

      I also went and met up with John today to borrow his scope to analyse the signal generator output, so the ignitor thread has had an update also and I now have a better understanding what's going on there.

      My housemate brought the GS650G Katana seat back with him today that I bought from eBay and while the shape of the rear isn't quite what I was expecting, it should be sufficiently longer than the OEM seat to do what I want.





      I'll need to cut a bit of the plastic underneath to allow it to sit on the frame rails properly, and I may be able to use the levers that are on there already to secure it.

      Even though the cover's in pretty good shape, it has a few tears and things and of course the red won't suit so it will need recovering, but the foam actually feels pretty good.

      I'll also need to drill out the rivets for the front tang so I can adapt something there to fit the frame on the 450 but that shouldn't be too hard.

      I threw it and the tank on and took some more pic's and I'll do some editing of these at some point to see how it will look if I make an embedded tailight to fill in the rear of the seat and also to bring the seat down to where it will actually sit on the frame rails:

      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


        Wow Pete, this is th first time I'm seeing this thread (noob to the site). Great work! I'll be watching from here on out.

        Comment


          Cheers Rich! I'm very keen to get this spark thing sorted and move on, very frustrating at the moment when I have so much more to do...

          I just had a look and realised I missed your first post with the GR's! No idea how I missed that, but I will go take a look now...
          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


            Great work Pete. I'm really enjoying your progress.
            Cowboy Up or Quit. - Run Free Lou and Rest in Peace

            1981 GS550T - My First
            1981 GS550L - My Eldest Daughter's - Now Sold
            2007 GSF1250SA Bandit - My touring bike

            Sit tall in the saddle Hold your head up high
            Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
            and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

            Comment


              Nice work Pete, you must be as happy as a dog with a belly full of pee and a street full of lamp poles.
              Still trying to get to grips with the exhaust, it will grow on me once the real deal is on I guess.
              Keep up the good work.

              Comment


                Originally posted by cowboyup3371 View Post
                Great work Pete. I'm really enjoying your progress.
                Cheers Cowboy, nowhere near as close as you are unfortunately, but it's definitely getting there!

                Originally posted by Flyboy View Post
                Nice work Pete, you must be as happy as a dog with a belly full of pee and a street full of lamp poles.
                Still trying to get to grips with the exhaust, it will grow on me once the real deal is on I guess.
                Keep up the good work.
                Hahaha I like that... and yeah that's pretty true indeed.

                I think the exhaust will end up a little longer with a muffler, and yes it's not quite right in cardboard.

                Once I get some image editing done I hope it'll look a little more like I envisage the end product, although I am a little challenged in the editing side of things.
                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


                  After doing some more work on the ignitor issue, I took the 5 minutes to remove some of the seat hardware. Unbolted the latches and drilled out the rivets holding the tang on the front:



                  I must say that hand drill is coming in very handy. No noise drilling is great at night
                  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


                    I've neglected to update this thread for a few days, so for those following this that aren't following my ignitor thread, I actually got some spark happening last night.

                    It's a bit early to say if it's a proper solution or not, but it's definitely heading in the right direction!
                    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


                      So... here's the circuit I'm currently using for the ignitor replacement, but I witnessed some ghost sparks tonight so I'm not sure it's quite right yet:



                      And this arrived in the mail today too:



                      I used a multimeter to map out all the wiring connections so I can hook it up in place of the old one, so now all I need is to find a choke cable for it and work out how to adapt that to my carb.
                      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 may have missed it, but where are you from?

                        Edit: I'm blind. You're in Australia. Duh.

                        Comment


                          All good Rich, plenty of times when I'm blind like that too

                          Sometimes there's even alcohol involved...
                          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


                            Spark time tonight, looking like I'm on track for the first start attempt on Saturday

                            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
                              Spark time tonight, looking like I'm on track for the first start attempt on Saturday

                              Good.Hoping this goes well after all your work.

                              Comment


                                Originally posted by SVSooke View Post
                                Good.Hoping this goes well after all your work.

                                Cheers for that! Me too
                                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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