1981 GS450E Rebuild

[pete]

Its looking awesome pete!!

what are you going to do with the fenders?

Thanks mate!

And nothin', they're all done and dusted I know the front's not perfect but it will do until I get sick of it...

[7981GS]

I hadn't noticed before.
You are using a dirt bike front fender?

Daniel

[pete]

I hadn't noticed before.
You are using a dirt bike front fender?

Daniel

Haha yup sure am Trimmed front and back... it's a bit less than perfect but will do the job for now at least. I'm hoping once I get a real tyre on there it will look the part a bit more... definitely not working with that Michelin road tyre...

[pete]

More seat shaping tonight, it's really getting close now. Hand sanding it is indeed a very tedious and slow process, but it's getting there slowly. I think I'm going to be able to just make sure all the main shapes are taken care of and then hopefully I can get the upholsterers to finish the little tidying up bits that I'm sure they have a better technique for than I do.





Then I got the carb overflow hoses back on the carbs and routed them to the right side of the frame and strapped them to the downtube:



Next I got my new fuel tap and accessories out ready to install:



And mounted, first time in a loooong time:

[pete]

And thanks to John I picked up one of these when I went up the road this morning:



I ended up mounting it above the K&N's. I cable tied it to the little harness support that pokes out the front of the frame cross tube with the rubber on it to support the tank:



That was the most out of the way place I could find for it where it shouldn't interfere with the throttle cable or the harness. I can't find the clamp for the valve cover end of the hose at the moment but I honestly don't think I'll need it anyway.

It's pay day this Tuesday, which means I'm planning on making a 'phone call to a certain shop to get me some Pirelli tyres ordered so I can take my wheels over on Saturday to have them fitted (providing of course they open Saturdays!)

Also, I attempted yesterday to go and have another look at the fly screen I've had my eye on only to discover they've taken off their website. I shot them an email and got an almost immediate reply that they sold the last one and won't be stocking them any more... bugger! Back to the drawing board on that one...

[7981GS]

It looks like you are doing a great job on the seat.




Daniel

[Flyboy]

+1, that seat is coming on really nicely Pete, you really are getting close to swinging a leg over it very soon.

[pete]

It looks like you are doing a great job on the seat.

Daniel

+1, that seat is coming on really nicely Pete, you really are getting close to swinging a leg over it very soon.

Thanks guys, yeah, I think it's really taking shape now.

At this point I'm thinking I'll try to work from home on Friday which will allow me to duck up to the upholsterer as they're only 5 minutes up the road.

[drivera84]

pete, how can you stand not taking her on a ride as is?


looking at how you are almost done, I dont think I would be able to...

[pete]

pete, how can you stand not taking her on a ride as is?


looking at how you are almost done, I dont think I would be able to...

That front tyre was on there when I got the bike in about '98 and that rear tyre was slippery in the wet with lots of tread... I ain't ridin' nowhere on her 'til I get fresh rubber

And yes, there's a chance I may "forget" she's not registered and take her for a shake down run once she has new tyres and I have the seat back

Which reminds me, I must do static timing of the Dynatek! It's just sitting there at the moment...

[Collo]

We seem to be doing similar projects at the same time - I'm also doing the seat cushion but not so confident about upholstery work so might leave that part. Your bike is looking great and the wait will make the first ride all the more worth it.

[Leigh]

Are we there yet?
Are we there yet?
Are we there yet?
Are we there yet?
Are we there yet?



So bloody close now, Pete.

[pete]

We seem to be doing similar projects at the same time - I'm also doing the seat cushion but not so confident about upholstery work so might leave that part. Your bike is looking great and the wait will make the first ride all the more worth it.

Yeah it looks like we are about the same place actually, and as for the upholstery, yeah, certain things I think are best left to the professionals unless you're confident you can do it right. I figured the same for the exhaust which is why I went to Tranzac...

Thanks mate, I'm real happy with her so far and am definitely looking forward to that first ride!

Oh, and I solved our problem of where to mount that breather filter too

Are we there yet?
Are we there yet?
Are we there yet?
Are we there yet?
Are we there yet?



So bloody close now, Pete.

Bloody oath Leigh! Getting all excited and antsy and hopping up and down and stuff and just can't wait to make that phone call to order the tyres and get the seat finished off and up to the upholsterers and get the hand grips on and set the Dynatek timing and fill her with oil and... I think you get the picture... just like Big Kev used to say... I'm excited!

[Hoosier Daddy]

Too bad we all aren't close enough to get a "Package Deal" on upholstery... I'm right there with ya!

[pete]

This is tonight's end result:



The ugly untouched, not cleaned, original horn mounted and connected and working. I wasn't intending to re-use this initially so I've done nothing to make it look nice, but seeing as it works it can go on for the safety certificate so I have less to worry about.

I found the issue with the horn wiring and when I swapped the stock plug over to the newer GSXR left control, I had the wire that's supposed to ground the horn connected to the wire in the harness that's for a passing switch instead which my bike doesn't actually have. Swapped that over to a ground wire instead and all set and fixed.

I also found a couple of pieces of foam on the base of the seat were coming adrift from each other so I gave them another go with the contact adhesive and so far so good.