82 GS450E Scrambler from Aus - Done!

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Big Rich said:
Whoa man! I'm excited about this Pete! Shame about having to go to plan B, but at least plan B wasn't junk the whole project.

Good job on the guard too!

Cheers Rich, me too! Can you tell I'm getting more desperate to get this done? ::)


Yeah plan B I think will be a good one, and at least I'll end up with a professional product on there that doesn't rely on my dodgy soldering... definitely want to return to the HEI challenge though as that's bugged me enough I want to finish it...


And thanks for the guard compliment :) I'll be happy once I've cut it down and have a good shape/size going on, then I'll be pretty much ready for paint prep which will be the fun bit...
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Haven't gotten much further at all yet, very minimal time last couple of nights, but I did at least get to sand down the spacer for the rotor a little so the advance mechanism now works like it should instead of binding on the bolt to stop it rotating.
 

Hoosier Daddy

Earache my eye...
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Small bites out of the elephant gets it done.
I try and do something every night, regaurdless how small. Like tonight for example I bolted on the front caliper mounts... big deal, 4 bolts. But the Zook is one step closer. ;)
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Hoosier Daddy said:
Small bites out of the elephant gets it done.
I try and do something every night, regaurdless how small. Like tonight for example I bolted on the front caliper mounts... big deal, 4 bolts. But the Zook is one step closer. ;)
Yes! My philosophy exactly... add those one little bit nights together, add in some full on progress nights and days and you get a heap done before you know it! Even if you don't, the next time you get to a full on night/day, you're surprised how well it goes as there's that little bit less to do, makes it a lot less daunting during a whole rebuild.

So speaking of that little progress...

Got a stand alone oil pressure switch wire sorted so I still get a warning light when using the Dynatek. The wire for it is part of the wiring for the stock signal generator, so I just put some bullet connectors in on the gauge side of the connector for the gauges so I could join them for the stock set up or split them so I can hook in the stand alone wire for the switch:





Cable tied it to the Dynatek wiring so I can route them together and will get some sort of sheath for it later on:





So I'm all set to keep hooking the Dynatek up now, hopefully I'll get some more done tonight but we'll see.
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

So the Dyna is all hooked up now and coils mounted etc.











Oil pressure switch works too:





So I'm ready to do the static timing.


Didn't have a battery available tonight so I hooked up an old PC power supply, but it doesn't have enough guts to do the static timing, but just enough for me to see that the oil pressure switch works ok.
 

Big R

Heaven is so far away.
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Holy cow Pete! Did you put all those kilometers on there!?

Looking good so far.......for some odd reason I'm really excited for you to get this thing on the road. I can't make it out on my phone, but do you have a weeping oil leak around your headcover? Looks like it's leaking upwards.......
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Big Rich said:
Holy cow Pete! Did you put all those kilometers on there!?

Looking good so far.......for some odd reason I'm really excited for you to get this thing on the road. I can't make it out on my phone, but do you have a weeping oil leak around your headcover? Looks like it's leaking upwards.......

Nah I only put about 10K on there when I was riding. Bought it from a pawnbroker so no idea of its history except that it has a GSX250 R/R on it and someone put one of the brake caliper axle dust boots on backwards...


I actually rode it for work for about 6 months which was fun, was riding all around South East Queensland here fixing computers so I got lots of riding in.


It's exciting because of those pipes... and because I keep carrying on about it... hahaha


I believe the gasket needs to get some oil into it before it seals well, and because I haven't been able to get the engine nice and hot yet, the oil hasn't burned off the valve cover there. At least that's what the general consensus is when I raised it in my rebuild thread over on GSR and that's what I'm hoping :)


So far it looks like tomorrow is Dynatek test day, haven't gotten in the garage at all to do the static timing so I'll be doing all that tomorrow and I just hope I haven't missed anything so it's all set to go...
 

Hoosier Daddy

Earache my eye...
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

*sending good vibes to Queensland*
C'mon baby ... start!
Start and charge would be even better! ;)
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Hoosier Daddy said:
*sending good vibes to Queensland*
C'mon baby ... start!
Start and charge would be even better! ;)
Thanks mate! I'm hoping for the best... few hours and we shall see! Gotta do a bit of work from home then I'll be into it...
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Bugger! Nada, zip, zilch...


It ran a couple of very short times on the choke today but that's it, would not idle or run, couldn't rev, blah blah blah...


I think it's actually too lean on the pilot circuit though as everything spark wise checks out, compression is good, plugs are good, etc. etc. but it just won't start and run.
 

Hoosier Daddy

Earache my eye...
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Son-of-a-BITCH!
So she barks but wont run? Sure you're getting enough fuel? As in bowls are full? Will she run for a short on a shot of carb cleaner? (wouldn't use either aka: "starting fluid" tis wicked stuff to an engine if not used in severe moderation)
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Yeah just can't win. I don't really understand how it used to idle (crappily) with my HEI setup but now I could only get a couple of brief starts with the choke on, but if I can have a timing light fire on both plugs while it's cranking, then it definitely has spark.

I got a mouth full of fuel making sure my temp. tank was feeding the bowls, and dropping the bowl drain plug let fuel out, so definitely fuel in there.

I did notice it starting to cranka bit easier after it wouldn't start any more so I'm wondering if the rings are starting to bed in and if that will affect it.

Hope to order some new pilots and mains for it...
 

Big R

Heaven is so far away.
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Hmmmm. I don't really know where to start.

Plugs wet? Proper compression? Visible spark at the plug? Obviously I'm just stabbing in the dark......I've got faith in ya though Pete!
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Big Rich said:
Hmmmm. I don't really know where to start.

Plugs wet? Proper compression? Visible spark at the plug? Obviously I'm just stabbing in the dark......I've got faith in ya though Pete!
Sorry, didn't put the same detail on here I did on the GSR, didn't quite have the time...

Plugs aren't wet, both plugs spark when out and grounded to the head and the timing light fires with them in when it's cranking, so I figure I can't do much more than that to verify sparks are ok.

http://s594.photobucket.com/albums/tt26/starpoint73/GS450/Dynatek/?action=view¤t=054.mp4

http://s594.photobucket.com/albums/tt26/starpoint73/GS450/Dynatek/?action=view¤t=055.mp4

Compression is really good too.





I wouldn't have faith in me at this point Rich, this is where I start into uncharted territory for me...

At this point I'm thinking get some bigger pilots and mains and just suck and see...
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Well I did actually get something else done...

Trimmed the front guard a bit:



Got the Ikon shocks on and boy wasn't that fun doing the left one... couldn't quite work out how to get the pipes off so I had to rest it against the left case cover with a towel for protection. I think I need a second set of hands to separate the left header from the collector to get them off fully. I also had to chuck some washers in behind the bracket as the Ikon springs are about a quarter inch larger in diameter than stock.







Then I chucked everything I have on to see how it's shaping up and the only things missing now is a mesh headlight grill, fly screen, mirrors, and hand guards. I still need to replace the headlight yet too but at least I have one for mockup purposes:







Definitely taking shape, but I'm reaching a point where I've gotta start finishing off the little things that aren't quite done yet.

If I could get it running right, that would take a load off my mind and let me concentrate on those little things too. At least I have most of the bigger budget items taken care of...
 

Big R

Heaven is so far away.
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Sorry Pete- I miss a lot over there. I know what the problem is! The ring of oil, ceremonial burning tires, and sacrificial virgins!

No? Ok.......I'm gonna guess a not-fully-charged battery. But I'll head over the GSR and look for some more details.

For what it's worth, this has always worked for me when rebuilding an engine: make sure the throttle is stuck at wide open. Then mess with it for a couple hours after having a 6 pack or so. Some swearing, cursing, head banging on the wall, etc- all helps. Make sure there are no baffles in the muffler and it will roar to life at 3 am. Then fumble for the ignition/ kill switch.
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Big Rich said:
Sorry Pete- I miss a lot over there. I know what the problem is! The ring of oil, ceremonial burning tires, and sacrificial virgins!

No? Ok.......I'm gonna guess a not-fully-charged battery. But I'll head over the GSR and look for some more details.

For what it's worth, this has always worked for me when rebuilding an engine: make sure the throttle is stuck at wide open. Then mess with it for a couple hours after having a 6 pack or so. Some swearing, cursing, head banging on the wall, etc- all helps. Make sure there are no baffles in the muffler and it will roar to life at 3 am. Then fumble for the ignition/ kill switch.

All good Rich, you're used to DTT, I'm used to GSR... I tend to go there first because I've been on there so long... May 2005 join date apparently although I was a member before then as well and it lapsed at one point...


Anyway, I reckon I need to try your method, that sounds like some serious fun!
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Dynatek Time and Suspension is here

Oh, and the plan at the moment is to go 2 sizes up on pilots and 4 sizes up on mains as a starting point...
 

Big R

Heaven is so far away.
Re: 82 Suzuki GS450E Scrambler from Aus - Rocking the Ikons and She No Run

Be very careful about that pilot size - I don't think I've ever gone up more than 1 size. And usually that one size was to correct the "factory" lean condition.
 

peteGS

Zuk's Rock!
Re: 82 Suzuki GS450E Scrambler from Aus - Rocking the Ikons and She No Run

I was initially thinking one size up, but with the mixture screws out 3.5 turns and still not firing as well as other comments on the GSR about needing to go up several sizes with pods and pipe, I think it won't be too bad a starting point.


In fact the thread that pointed me in the right direction for what jets I actually need mentions going up huge amounts of sizes, but I think he was using far less restrictive pipes than I have.


Basically, at $8.50 a jet, I want to reduce the number I'm buying as a starting point, and then I can get a better idea once it's actually running.


I'm also thinking that a lot of guys go 3 turns out with the factory airbox and factory pipes just so it's not lean any more, so that's getting towards 1 size up already right there, so to my uneducated/inexperienced brain it says 2 sizes *should* be a good starting point...
 

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