Suzuki GS450 --- Cafe Build

[Flaming Chainsaws]

Ugh... The OP deleted my build thread... Here we go again! I'll fill it in tomorrow. This time, nothing will happen to it.

NOW YOU CAN POST!

[Flaming Chainsaws]

Let's start from the beginning.

Here is what I started with. A rusty 1980 Suzuki GS450L. As you can see, it's missing a few parts.

6-4-10

[Flaming Chainsaws]

6-5-10
Ordered a brand new YB10L-A2 battery from Amazon.com. $50.

6-6-10
Cleaned up the chain guard.




6-15-10
Received the battery but did not get any battery acid.

6-16-10
Went to O'Reilly's to buy a liter of battery acid. $8.42. Added the acid to the battery then charged it. Brought it back home to my bike, put the battery back in, and she runs!

http://www.youtube.com/user/SpidershotgunX#p/u/25/kvJ-1owfPus

7-14-10
Scottychop brought a few parts over. This includes: 1980 Suzuki GS450L gauge cluster, 1981 Suzuki GS450E turn signals, EMGO mirrors, and air filter. Got them installed.






7-23-10
Weatherstripping arrived. Sealed the airbox and got new screws for the airbox clamps.

[Flaming Chainsaws]

7-26-10
More parts from scottychop. Coils and lower handlebars.






Working tachometer.

http://www.youtube.com/user/SpidershotgunX#p/u/18/myw_h7lvisE

8-1-10
Fixed no spark problem by cleaning the igniter connections.

8-4-10
Went to O'Reilly's to buy some electrical wire to hook up the gauge cluster.




8-7-10
Bought a 1157 bulb. Rear running light and tail light works.

8-29-10
Ordered a 1975 Honda CB550 headlight.

9-3-10
Installed the GS450E turn signals on the rear.

9-4-10
Bought an EMGO cafe fairing for $10 from craigslist.

[Flaming Chainsaws]

9-9-10
Met up with the previous owner of this GS450. Learned about it's history and what's been done to it. He gave me some parts for free. Brand new coils.

Super fat blue spark.






9-13-10
Headlight arrived. They gave me a chrome 7" EMGO headlight instead. New turn signals too.


9-17-10
Bought bar end mirrors.

[Flaming Chainsaws]

10-17-10
Dissassembled the carburetors. Preparing for rebuild with Mr. Robert Barr's o-ring kit and Berryman's carb cleaner.


10-18-10
Reassembled the carburetors with new o-rings. Happy birthday to me!

10-19-10
Replaced the intake boot o-rings.

Old o-ring.


New o-ring.


11-1-10
Primed my spare front fender.


Painted gloss black with clear coat.


Installed on bike.

[Flaming Chainsaws]

11-2-10 to 11-3-10
Polished the fork lowers with Mother's Mag & Aluminum Polish.

Before.


After.


11-5-10
Polished sprocket cover.




11-7-10
Received EMGO pod filters.


Removing the air box in one piece.


Pod filters on!

[Flaming Chainsaws]

11-9-10
Clubman handlebars.






12-1-10
Hit and run accident. Broke a few parts.

Picked these up at a Harley shop.


12-4-10
Received 1979 Suzuki GS400 gas tank from SVSooke.

Sanded down.


12-11-10
New horn and grips.




12-13-10
Cut off the coil mounts.


Smoothed it out.


Cut off the front gas tank mount and smoothed it out.

[Flaming Chainsaws]

12-15-10
Painted my rims semi gloss black.


Yoshimura sticker on rear wheel.


Red pin stripes.


Received cafe racer seat from Hotwing Glass.


12-16-10
Rims, seat, and gas tank on bike.




1-4-11
Cut off front seat hoop.




1-14-11
Received EMGO headlight fork ears from johnny gaijin on Do The Ton.

[Flaming Chainsaws]

1-17-11
Headlight fork ears on.


1-18-11 to 1-20-11
Did work on gas tank.




1-25-11
Ignition system test. Everything is good except for the igniter.

2-3-11
Received coil packs, igniter, R/R, and starter solenoid from eBay.


2-5-11
Received rear brake/running/tail lights from eBay.


2-9-11
Rattlecanned gas tank satin black.


2-20-11
License plate bracket and LED license plate bolts.

[Flaming Chainsaws]

3-4-11 to 3-6-11
Replaced electrical connectors on wiring harness. Wiring harness wrapped with tape.


3-15-11
Brand new igniter. Bike runs .


3-18-11
Drilled holes in seat pan.

3-21-11
Put LED lights into holes.


4-18-11
Velcro on frame and seat pan.




4-20-11
Got side covers and bar end mirror.

[Flaming Chainsaws]

4-21-11
Bar end mirror on.


Side covers on.


4-25-11
Side covers and seat primered.




4-26-11
Wet sanded primer with 1500 grit. Sprayed gloss black on seat and side covers.


Mocked up on bike.




4-27-11
Replaced missing brake return spring.

[Flaming Chainsaws]

5-2-11
Bled the front brakes.






5-3-11
Sanded off the crappy rattlecan paint.

5-3-11 to 5-5-11
Bondo on gas tank. Super smooth.

Sneak peek.

[Flaming Chainsaws]

Whew! That was some hard work getting all the pics back in here.

So today, I bought these gloves. Getting my riding gear .

http://seattle.craigslist.org/see/mcy/2357153243.html

Then I placed an order for duaneage's R/R. Hope it will get here next week!

[FreshStart]

Your just all about breaking records huh? First build thread had record views and now youve had 3 build threads on 1 bike... gonna run tonight at the drags?