1987 gs450l

[Robert West]

So, I begin with pile of parts that I'm told is a motorcycle.



My first step, obviously was priming and painting the frame.

[Flyboy]

Yep, sure looks like a motorcycle to me, a bit of air in the tyres and a good wash and she should be good for the Sunday morning breakfast run.

What are the plans for the build, stock, cafe....?
Looks like any free time you may have had is now at a premium, I will be following this one with interest, it is always good to see a bike in boxes make it back onto the road, keep the updates coming.

[pete]

Definitely keen to follow along on this one Robert, keen to see what you do!

[Robert West]

The bike is going back together stock. Not a restoration, but I don't plan any customization.

The frame is now painted. I used Rustoleum Appliance Epoxy but I didn't like how shiny it came out so I scuffed it up and topped it with some flat black.

I've got it sitting on tires now.



One question though, what next ? Wiring harness ?

[Big Rich]

I would say the motor unless it is getting work done to it. But if you do go for the harness, try to get some of the other electrical parts in first. Like the coils, tail light, battery tray, etc. Then you will know where each connection needs to end up.

And in my experience, appliance epoxy doesn't hold other paints well. Maybe since you scuffed it you'll have better luck than me though.

[pete]

That definitely looks more like a 450 than it did before

I'm with Rich that I would do the motor next.

The way I did mine was the frame and wheels first as they're somewhat necessary to the whole idea of a bike.

Next up, I tackled the motor, otherwise if I did other stuff before the motor and then discovered the motor was no good, I may have just wasted a whole bunch of money and time... but that's just how I did it...

[Robert West]

I'll certainly follow your advice and hit the motor next. I'm told the motor is good and that there was nothing wrong with it when the bike was disassembled. I'm hoping to get the engine fired up before really breaking loose a bunch of money on this thing so I'm trying to get it to a state where I can start it and run it with minimal expense.

For instance, the forks still need work and I've not replaced the brakes yet. I don't mind doing extra work, but would rather not spend a bunch of money if the engine isn't any good.

So .... Engine next. Which means its time to start on the carbs.

Thanks for the advice and I'll certainly be asking for a lot of it. I probably wouldn't even attempt a project like this were it not for this website.

[Big Rich]

Just curious, do you know the easiest way to put a twin in the frame? Laying the motor on it's side, fitting the frame around the motor, etc, etc?

[Robert West]

I've never done it, but I'm sure by the time I get that motor set in there I'll know all the wrong ways to do it.

[Big Rich]

Ha! I think the service manual just shows somebody lifting it out of the frame. Forget about that. Wrap the frame around the engine with pipe insulation or a cut up garden hose to protect the paint. Lay the motor on a really think blanket or something and get a hand to work the frame over it. You'll get it.

[Robert West]

After reading about how hard it is to remove the airbox with the engine in, I reckon the battery box and airbox should go in before the engine ... right ?

[Robert West]

The battery box and airbox are in. Next up is ordering some parts (airbox boots, o-rings, carb stuff). Carbs get rebuilt and I unpack the engine and start cleaning it.

[pete]

Sounds like you're getting somewhere!

Didn't realise noone had answered your question about the airbox... and I'm not putting my airbox back in so not sure, although I do know it was a pig to get out.

[Robert West]

I put mine in, but didn't bolt it down. I figure that'd be the easiest way. Everything is still moving forward so that's good.