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1982 GS450L Rebuild/Mod

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    1982 GS450L Rebuild/Mod

    I got the bike from a marine who had bought it from the original owner. The bike was the marines first and he put about 7,000 miles on it bringing the total miles to about 14,000. About a year ago the marine was riding and he heard a loud pop and started leaking oil. He had a friend tell him it was the piston and would be super expensive to fix. So he ended up getting a new bike and let this one sit for a year. I was working on a friends short film next door one day and met the owner, chatted for a bit, and he tells me that I can have the bike if I could get it out of his place. So he signs the title over to me on the spot and I throw it in the back of our equipment truck. Cosmetic wise the bike was in pretty good shape no real rust on anything except the exhaust. I put a new battery in, new oil, new gas. It started right up. I have no real knowledge of motorcycle maintenance (this is my first bike) but I grew up riding dirt bikes and working on my own car. Back to the bike though, it ran up to about 50 mph and the tach was almost non responsive. I pulled the plugs and the one on the clutch side was covered in oil. A few days later a friend of mine that works on bikes took the top off the motor while I was out of town, he said there was a hole in the head of the clutch side piston big enough to put a pencil through.

    So I set up shop in my new place the last couple days and turned a old unfinished laundry room and the space under the house that leads to it into my own little workshop. I'll post some pics today or tomorrow if I can get to it. My plan is to (sorry gs purist out there) modify the bike by lowering the rear end, chopping the rear fender a bit, dishing the tank, straight pipes (baffled) two tone paint job Black and Gun Metal. I've got a few pics of the look I'm going for I need to re-size and I'll throw them up here for you guys. I've attached a pic of what it looked like when I got it.

    Since then I have removed everything. It's just a naked frame now and a pile of organized parts. The frames got a little rust in some spots as well as in the battery tray. I'm thinking I'll get it blasted and re-paint it black. Then slowly (still paying back student loans) I'm going to replace all the necessary parts for what I want and sell or discard my excess. Everything that was on the completely stock bike is in good order except for the handle bar starter/kill switch. It starts no matter what position it's in.



    This is what it looked like when I got it:

    http://www.thegsresources.com/_forum...9&d=1317674243

    More pics to come later today of the tear down progress!

    #2
    Subscribed Greg, keen to see what you do with her
    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

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      #3
      Good base to start from!! Not bad!!

      Comment


        #4
        subscribed too....like to see where this is going!

        Comment


          #5
          Ok guys, I've had a rough time getting some pics to you but here they are finally.

          This is how I got the bike, completely stock with a rattle can paint job. (the signals, brake light, rear fender and mirrors were included in some saddle bags)





          Then I stripped her down






          The Keeper Pile




          Most of this will be sold or trashed (except the wiring harness) Basically just cables, gauges, muffler tip, stock seat, horn, also not pictured but included in this pile are the turn signals and brake light/license plate bracket. I'm also gonna put smaller shocks on so those stock ones will be sold as well.



          My makeshift workshop/man cave. It was an unfinished laundry room under our house here at the beach (the room in the back of photo). Took some old doors and saw horses and made a work bench. It's got power to run my mp3 player and light already hooked up. The best part though is that the air return from the dryer in the house runs into this little workshop of mine. Which will be great for this winter!




          So this is where I'm at so far. I guess my next step will be to sand and re-paint the frame and clean up the 30 year gunk that was covering everything else pulled off.

          An interesting side note, I found the manufacture info on the frame and this bike (82 gs450L) was actually made in November of 81. So she'll be turning 30 next month. Nothing seems more fitting to me than to give her a good complete rebuild to celebrate the occasion.

          More to come soon guys, I'll keep ya posted!
          Last edited by Guest; 10-06-2011, 01:22 AM.

          Comment


            #6
            Good stuff Greg, glad to see you getting some things done

            Your bike's one month younger than mine, mine's 10/81.

            I was hoping to have her done for her 30th birthday but I don't think I'm quite going to make it.

            I should have some new clothes for her at least...
            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


              #7
              Progress Report: I've been working a lot lately. Which is good for my wallet, but it's killing my wrench time. I've got all the parts that will be put back on the bike all cleaned up. (shocks, wheels, handle switches, triple clamp, battery tray) I've got the frame and swing arm all sanded down and hit it with a coat of primer. I'll do another coat and then hit it with a high gloss black and some clear coat. From there I'll put together a rolling frame and get to work on taking off what I don't need on my wiring harness. Pics coming soon!

              Comment


                #8
                Good stuff, can't wait to see! I just got done with my paint job today aside from the polishing...
                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


                  #9
                  Primed Parts



                  Primed Frame

                  Comment


                    #10
                    Fresh Paint on the Swing Arm and Frame





                    Comment


                      #11
                      Looking better all the time
                      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


                        #12
                        Progress Report: Got a few coats of satin black on the frame and swing arm. In the middle of cleaning up the wheels and shocks/forks right now. Hopefully I'll have a roller in the next few days.



                        Quick question for you guys. How many coats of paint should I put on the frame/swing arm? Right now they have received one light coat and one thick coat. Also, I'm looking to drop the rear end about an inch or two. I've heard suzuki savage shocks bolt right up and are about 10.5" instead of my stock 12.whatever" Only problem is I cant find any cheap ones online. With my student loans kicking in I can't aford to drop 150$ on some. I was also thinking that if I cant find any shorter shocks for cheap I could maybe modify my stock ones? cut the spring and shorten the shaft? What do you guys think?

                        Comment


                          #13
                          Originally posted by GregNC View Post
                          Progress Report: Got a few coats of satin black on the frame and swing arm. In the middle of cleaning up the wheels and shocks/forks right now. Hopefully I'll have a roller in the next few days.

                          Quick question for you guys. How many coats of paint should I put on the frame/swing arm? Right now they have received one light coat and one thick coat. Also, I'm looking to drop the rear end about an inch or two. I've heard suzuki savage shocks bolt right up and are about 10.5" instead of my stock 12.whatever" Only problem is I cant find any cheap ones online. With my student loans kicking in I can't aford to drop 150$ on some. I was also thinking that if I cant find any shorter shocks for cheap I could maybe modify my stock ones? cut the spring and shorten the shaft? What do you guys think?
                          Cool, although we need to see pic's

                          Can't comment on your shock question as I just replaced mine with Ikons, but as to paint, it really depends on what you're using.

                          I did mine with POR 15 Blackcote and it says 2 coats, so that's what I did and I think it turned out pretty well considering I was brushing it on.
                          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


                            #14
                            I'm using satin rustoleum rattle can metal paint. I just got done putting a 3rd coat on. Pics up later this afternoon!

                            Comment


                              #15
                              Oh and before I forget, I checked Robert Barrs website for the 450 carb kit everyone recommends and it says that it's not available. Ideas? Can I order everything in the kit separate?

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