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1981 GS450E Rebuild

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    Well... first of all tonight I cleaned up this little area as it should be perfect for somewhat of a little spray booth to spray the caliper and caliper bracket:



    I'll just tack up one of my old plastic drop sheets around the area and it should be good to go.

    In the process of cleaning that up, I found these that I'd forgotten about:



    Which are for here:



    Now, question is, I only have 3 out of the 4 that are supposed to be there (was like that when I bought it), so are these important and does it matter if I don't put any back on at all? The description on the parts fiche is simply "Rubber Pad", and I can't see any purpose they could serve that would be important enough for me to bother with them...

    Anyway, back to the gauge lights.

    These are what I'm replacing with LED's:



    If you've read up on Matchless' guide, you'll see his gear position indicator has a diode or rectifier on it, whereas mine doesn't have this, so one less thing to worry about.

    The good thing is that the way the gear position switch works, only one LED will ever be grounded at one time, so I can simply use one resistor for all six LED's which makes it a lot simpler.

    Now, this is the existing 6th gear bulb lit exactly as it is, although note that this is night and I have two desk lamps illuminating this area, so it's not an ideal indication of how it is in daylight:



    Then we have the 1500mcd LED:



    Not real flash at all, too dull, and you can clearly see the outline of the LED as well.

    Next up, 8000mcd:



    Much better, although possibly not quite bright enough.

    And the 20000mcd:



    Bit hard to tell from my crappy blurry pic, but it actually doesn't end up much brighter than the 8000 and the viewing angle is much worse, so the 8000 so far is the winner.

    However, it seems that Matchless may have ended up using some 13000mcd LED's and if so, that will more than likely be the ideal option as a compromise between the 8000 and 20000.

    One thing also not mentioned in his LED replacement guide is the use of zener diodes. I imagine these are to protect for over voltage and reverse voltage, but I'm not 100% sure on that as it's been too many years since I've played with this stuff to remember things like that.
    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 had an idea that I may be able to rip all the stuff off the original rear mudguard and it may be ok to use with a different brake/tail light on it.

      So, ripped all the original stuff off it:



      And popped it in place:



      I think if I use it, it'll end up looking like it has rather a large haemorrhoid... which is definitely not the look I'm after!

      I'll still need to source an alternate rear mudguard as well as a seat.

      The original front will definitely be fine though:



      Will need some paint and some minor dent repair:



      Not sure if you can quite make out the dent in those pic's, but there's a small one there as well as the crease that's fairly obvious as well. They should be reasonably easy to smooth out.

      So I quickly sketched up a little diagram on my now very handy whiteboard and took some measurements for the rear mudguard:



      The 45 degree line there from the rear axle is the legal requirement for the rear mudguard coverage here in Queensland.
      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


        And finally for tonight I popped the tank back on and took some more measurements for the seat:



        I made sure I have pic's of the whiteboard diagrams on my phone as well so I have the measurements handy.

        If I get to a wrecker next weekend I should hopefully be able to find what I'm looking for. No guarantees on getting time for that though of course.

        I also had a look around this morning at other sites in the US for the caliper components I need, and it looks like if Boulevard Suzuki don't come through I might as well order them locally here.

        Either the prices are $10 to $15 dearer for each component or the postage is absolutely ridiculous, and I mean $130 to $140!!! Insane.

        At the end of the day it will mean I save very little on buying the parts here, and in some cases I will end up paying a lot more.

        Fingers crossed Ashley from Boulevard Suzuki has just been on leave and will be back on Monday...
        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


          Those rubber bits are to stop the fins from 'ringing'.Throw back from Suzi's 2 stroke days.Don't do much so I wouldn't bother with them.

          Comment


            Originally posted by SVSooke View Post
            Those rubber bits are to stop the fins from 'ringing'.Throw back from Suzi's 2 stroke days.Don't do much so I wouldn't bother with them.
            Now I have to go out and see if my 450E has any of them, although I don't think it does. Maybe I just never noticed.

            Comment


              Originally posted by davidduarte View Post
              Now I have to go out and see if my 450E has any of them, although I don't think it does. Maybe I just never noticed.
              LOL made me check the 3 400's I got here.None of the 80's engines do.The 79 has the ones betten the head fins.Suspect the other are MIA

              Comment


                Cool, knew they had to be there for something, I'll leave them off seeing as I only have 3
                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


                  Apparently it was mail day today. Got home to find a couple of parcels my wife was waiting on, several bills, and a parcel for me!



                  Pretty well packed for international travel:



                  One shiny new master cylinder with banjo bolts and washers:



                  And of course I had to put it on the 'bar tonight even though there's no braided line or calliper to attach it to yet:



                  So if I ever get my piston set etc. for the front caliper, then I should be laughing. Need to work out what angle banjo fittings I need for the braided line too and get it ordered.

                  They're cheap on eBay from the link SVSooke gave on an earlier post, but with postage added on I think it will be almost the same price to get it made locally here and I'll be guaranteed it'll pass the safety certificate. Wait and see once I measure it up and work the angles out.

                  So, I then trawled eBay and made a couple of purchases for my LED conversion for the gauge lights.





                  I should be right with these two as the flat top LED's have a much wider viewing angle and I don't think they'll be too bright as the resistor is a little larger than they require so should current limit them somewhat.

                  I also notice the viewing angle is "50% power", so assuming it won't give the full 20000mcd brightness either.

                  If all else fails, they were dirt cheap and I can get more.
                  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


                    Awesome, getting boxes of stuff in the mail is like getting Christmas prezzies.

                    And of course I had to put it on the 'bar tonight even though there's no braided line or caliper to attach it to yet:
                    Hahhahah, yeah, I know it, kind of like building a kite, and you have to fly it right now.even though there is not a drop of wind around.

                    Comment


                      Originally posted by Flyboy View Post
                      Awesome, getting boxes of stuff in the mail is like getting Christmas prezzies.


                      Hahhahah, yeah, I know it, kind of like building a kite, and you have to fly it right now.even though there is not a drop of wind around.
                      Exactly! And no I didn't squeeze the lever like I was braking, well... maybe I did a few times...
                      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
                        Exactly! And no I didn't squeeze the lever like I was braking, well... maybe I did a few times...
                        I used to twist my throttle like a maniac . That was when I first got my bike and was waiting for the battery. I soon found out that you have to roll on the throttle LOL!

                        Looking good Pete!

                        Comment


                          Cheers FC, I just hate this waiting... waiting for budget... waiting for replies to emails to order parts... waiting to get daylight hours to work on it... waiting to get a chance to visit a wrecker to look for a seat and rear mudguard... waiting waiting waiting... makes me mad

                          But alas, I will get there!
                          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
                            Cheers FC, I just hate this waiting... waiting for budget... waiting for replies to emails to order parts... waiting to get daylight hours to work on it... waiting to get a chance to visit a wrecker to look for a seat and rear mudguard... waiting waiting waiting... makes me mad

                            But alas, I will get there!
                            Funny. Me and SVSooke just had this little conversation . Waiting sucks!

                            Comment


                              Indeed... my patience is wearing thin with it all and I wanna ride this year...
                              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
                                I just stumbled across this... had to buy it

                                Potentially I'm a sucker but I don't think so...

                                http://cgi.ebay.com/ebaymotors/ws/eB...K%3AMEWNX%3AIT
                                Shoot, I bought the Suzuki shop manual from my local dealer for $45. I think i'm the sucker. It is pretty indispensable though.
                                Last edited by Guest; 05-13-2011, 02:46 AM.

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