1981 GS450E Rebuild

[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.

[Redneck]

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

[Matchless]

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!

[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

[spyug]

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]

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

[Matchless]

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!

[ndaugbjerg]

Pete,
Blame Spyug, he sent me looking for you. I'm starting a 450 cafe project. I have not been able to find a caliper kit; CycleBrake says they are no longer available. I found your thread regarding the 250 Ninja caliper and 550 rotor. Is this a match or will I need to fab a caliper carrier? That's not a problem. Are there other combinations for the 450 front brake. I never rode a bike with "too much" stopping power.
Thanks,
Niels (ndaugbjerg)

So, figured it was about time I put a proper rebuild thread in here for my 450.

This started way back in January 2005, after it had been sitting for a couple of years due to needing a new rear sprocket, chain, and rear tyre and not having the cash or time to get new ones.

This is what I started with:





This is where I'm thinking of heading at the moment, but that may change, and I'm also thinking blue rather than green:



Anyway, this is just the start and a lot has been done over the intervening years (very slowly though), which I will update over the next few days up to where I'm at now.

There's another thread in Appearance regarding engine paint that I have some pic's in too:

http://www.thegsresources.com/_forum...d.php?t=135476

[pete]

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

Hahaha thanks Andre... I think I'll bite the bullet and go the new one this time... however I'll hang onto the old one as I could always rewind it for a spare

And I'm 100% certain it's the stator now... each leg at 5K RPM was 56VAC, 52VAC, 48VAC... they were all around 75VAC when I tested the charging system before getting her registered...

Pete,
Blame Spyug, he sent me looking for you. I'm starting a 450 cafe project. I have not been able to find a caliper kit; CycleBrake says they are no longer available. I found your thread regarding the 250 Ninja caliper and 550 rotor. Is this a match or will I need to fab a caliper carrier? That's not a problem. Are there other combinations for the 450 front brake. I never rode a bike with "too much" stopping power.
Thanks,
Niels (ndaugbjerg)

Hey Niels, in that case Spyug's punishment can be sending me his 750 popup Katana

Have you started a project thread on it yet? Would love to keep up with how it's going.

As for a caliper kit, do you mean rebuilding the existing 450 caliper or replacing it with something with a little more stopping power?

If it's the latter, the key is whether you have 450L/T forks or 450E/S forks.

If it's an E or S, you should be able to get one of Salty Monks adapters, a left hand Kwaka twinpot caliper, a 550 or CBR disc, and have a nice brake upgrade.

This should be the thread you saw:

http://www.thegsresources.com/_forum/showthread.php?t=185121

And the measurements and things should be in this thread to help you make sure it will fit:

http://www.thegsresources.com/_forum/showthread.php?t=181521

I was thinking about doing it myself but so far I've been happy enough with the braided steel line and new master cylinder... let me know how you go though!

[ndaugbjerg]

Pete,
Thanks. You guys are going to save me a lot of tjme on this project. I scored an NOS master cyl. on ebay for $40. Also ordered new banjo ftgs. and steel hose and the piston seal and dust seal. Think I'll rebuild it stock,get it running and then look at upgrades. Took a shot and ordered 17/43 sprockets and a new sset of Bridgestone Spitfires for $109.99. I have the trunk of my car full of other goodies and I bring them in the shop one at a time; You understand. I've promised myself to photo document the build. One of the other guys is going to tutor me on the pic upload process. I think I was riding when Bill Gates was in diapers, so some of these things are a bit challenging.
Regards,
Niels

[pete]

Pete,
Thanks. You guys are going to save me a lot of tjme on this project. I scored an NOS master cyl. on ebay for $40. Also ordered new banjo ftgs. and steel hose and the piston seal and dust seal. Think I'll rebuild it stock,get it running and then look at upgrades. Took a shot and ordered 17/43 sprockets and a new sset of Bridgestone Spitfires for $109.99. I have the trunk of my car full of other goodies and I bring them in the shop one at a time; You understand. I've promised myself to photo document the build. One of the other guys is going to tutor me on the pic upload process. I think I was riding when Bill Gates was in diapers, so some of these things are a bit challenging.
Regards,
Niels

Good stuff Niels, that sounds like a good start.

The only non stock part of my front brake is I used a master cylinder from Mikes XS as mine was beyond repair. For second hand parts over here we typically need to get them from the US so I figured $US76 was a good price and got one with a 13mm diameter piston. Very happy with that so far.

If you have an E or S, I think the stock sprockets are 16/45...

To get your photos up, use this guide on BassCliff's site:

http://members.dslextreme.com/users/bikecliff/images/how_to_post_pictures.pdf

And Bill Gates in diapers hey? Hahaha nice! Glad to see you still riding

Oh, and I just found your intro post... can't believe I didn't see it earlier! Will post on there in a minute too

[ndaugbjerg]

Pete, You're right on the 16/45; just thought it would pull the 17/43 and drop the revs a bit. If it struggles, I'll pop the 16 back on. Sorry you're so far away but buy a lottery tricket every so often, then you can join us on a Texas hill country ride. Of course that works both ways; I'd love to spend a month or two riding upside down.
Niels

[pete]

Pete, You're right on the 16/45; just thought it would pull the 17/43 and drop the revs a bit. If it struggles, I'll pop the 16 back on. Sorry you're so far away but buy a lottery tricket every so often, then you can join us on a Texas hill country ride. Of course that works both ways; I'd love to spend a month or two riding upside down.
Niels

Definitely let us know how it goes with that gearing. I have no dramas with the stock gearing but a bit of extra knowledge and experimentation never hurts

I'd love to win the lotto and come for a visit... I'd have to win enough to ship the 450 over and ride it around and visit all the guys on the forum who have helped me so much along the way... and yes a ride in the Texas hill country would be cool and I reckon we could drag Chuck Hahn along as well and you could both leave me behind

[pete]

Managed to get myself in the doghouse tonight so... that meant I got a little time in the garage...



It finally fits...



Got some filing ahead of me to take off the sharp edges and get some final little shaping touches done, then it's glue on the rubber and bolt it in time...

I expect to order my stator on Wednesday too which means in theory I should have it in time to hopefully install on Saturday and I can have a functioning charging system again...

In the meantime, I've got an industry certification I have to upgrade which means I have an exam on Wednesday... can't believe I'm nearly 40 years of age and still taking exams! Geeez... the things we do for our employers hey? Oh well... looks good on the resume right?

That means I'm logging off in a few minutes to start studying... and I get Tuesday/Wednesday off for study leave, and unfortunately I really will have to study... I'm completely unprepared funnily enough...

[Redneck]

Managed to get myself in the doghouse tonight so... that meant I got a little time in the garage...



It finally fits...



Got some filing ahead of me to take off the sharp edges and get some final little shaping touches done, then it's glue on the rubber and bolt it in time...

At least you are banished to the garage when your in the doghouse. I end up having to watch my little princess while the wife goes and sulks about how mad she is at me....lol. Wish she would kick me out of the and into the garage...lol.

Oh well... if that is an aluminum pan, sand paper is much better at cleaning up the edges than a file comes out a lot smoother. If its steel hit it with the dremmel with the little grinding wheel.

Paul