GS450 "Sport" - Done!

Re: GS450 "Sport" - New brakes! :)

The twins on the front may be overkill, but damn they sure do look pretty. Any good ideas on a slotted/drilled rotor for the front of the 450? I was thinking of taking the tie to do t myself but I may be better off purchasing a nice replacement.

Gary
 
Re: GS450 "Sport" - New brakes! :)

Thanks fellas!

Gary, I swapped the single disc from my GR to a dual disc setup, and people said the same thing. My thought is: you can't have too much stopping power. There is a list somewhere on the GSResources somewhere about what rotors swap with others, but I haven't seen a difference other than the slots themselves. If you want to measure your solid rotor, I can compare it to one of my slotted ones though.
 
Re: GS450 "Sport" - New brakes! :)

Thanks Rich! I'll see if I can find the conversion on GSR. If not I should be with the bike over the weekend to get some measurements.

Gary
 
Re: GS450 "Sport" - New brakes! :)

Forgot to post this yesterday - finished painting and installing the crash bars. Good old black appliance epoxy!

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Today I have a bunch of small stuff to do: brake light wiring, petcock install, replace some bolts on the crank case, straighten up the headlight, etc.
 
Re: GS450 "Sport" - Success!

Ok, got a LOT done last night. For those of you not from PA, we got all of this yesterday morning:

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My new bolts came in the mail to replace all the JIS screws in the crank covers (don't ask about the Skull / Shell sticker.....long story):

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In the same package was a NOS petcock. The original leaked, and I found out why when I took it apart......the internals literally crumbled when opened up.

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New clutch cable (along with the replacement crankcase bolts):

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Wired up the front brake light switch, adjusted the clutch cable, disengaged the clutch safety switch, and bolted the headlight back up and got this:

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Re: GS450 "Sport" - Success!

So what does any of us do as soon as a project is able to hit the street? Yep.....took it for a ride. It was hell getting out of the driveway with all the snow, and I couldn't take any turns with any actual speed (it was 2am and there is still all kinds of snow / salt on the roads). And this is what happened after less than a block:

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The shift linkage snapped. I was in first gear when it happened so I was able to limp back to the garage. I noticed there was just a tiny bit of threads exposed on the broken end and thought "let's see what happens"......

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Good enough! Got to rip thru the neighborhood (all up hill from home in case I had to push it back......). Even got it up to 5th gear before my fingers got numb! Woot!

So now it's on the road. I'll be swapping out some stuff here and there, but it's basically done.
 
Re: GS450 "Sport" - Success!

Wooohoooo!!!! Awesome stuff Rich! Glad to see her all in one piece and riding :D


Bugger on the shifting linkage but that shouldn't be too hard to sort.


I got replacement heim joints from a hobby store for mine as they were shagged. Just had to take a dremel to the back and grind it off where they'd peened it over on the stock ones, and the hobby ones have a nut on the back so it's an easy swap.


Replacing the linkage should be easy too, pretty stock thread, M6 I think, so shouldn't be hard to find something to replace it with. If all else fails a left hand and right hand M6 tap and a piece of rod should sort that out too...
 
Re: GS450 "Sport" - Success!

Nice Rich. I need to get a bike on the road soon , this winter has been crap.
 
Re: GS450 "Sport" - Success!

Ok, got some other small stuff done. Sandblasted, painted, and mounted the GS500 head light:

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installed the license plate frame / brake light:

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Now that the headlight is installed, I could work on installing the quarter fairing. Since I won't be trying to color match the factory red paint, the fairing will just get a quick blast with appliance epoxy:

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Re: GS450 "Sport" - Success!

And I bought some frame clamps for the saddlebag mounts. Lower clamps:

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Upper clamps:

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Test fitting the saddlebag supports:

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Now that I know everything "fits", the supports got painted black to match the frame. I'm also working wiring in an auxiliary light to the crash bars. I wanted to go with an LED driving light, but finances won't allow that yet......I'll get pictures of it once it's done.
 
Re: GS450 "Sport" - Success!

Saddle bag mounts?You must be planning to take this thing on tour.
 
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