82 GS450E Scrambler from Aus - Done!

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

No sewing machine does make it tough for most seats... but check the long ass thread on my GL1100 "Bomber!" build, linky is in my sig. That one I streached the vinyl over the whole thing and used contact cement underneath... not a stitch in it. But I think its shape helped a lot.

Oh and PS... did you go to the "Rattle Can Bling" thread yet?

Will definitely have to go look at that then, although still thinking foam it myself and get it covered by someone else...

Haven't had a chance to get into the bling thread yet, but I will

Hey Pete,

Congrats on getting it started. Guess there's no need for the HEI modules anymore lol.

Cheers mate! Very happy indeed

I'll still work on the HEI modules as I promised a few people over on the GSR, but the Dynatek will definitely be my ignition of choice

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

Got into valve adjustments night before last and re-torqued the head nuts as well.

Looking good inside, no issues that I can see:

I really should polish or replace those head nuts, they really bring the rest of the engine down!

And for those of you with GS' and shims who don't know it, a cable tie makes swapping shims sooooooooo easy:

I only have to change one shim, should be here today or tomorrow.

Love it:

This is the main big deal here:

Those intake boots make such a huge difference!

The old ones have shrunk and it barely feels like the clamps do anything. Need to use rubber grease to get the carbs in but they still felt pliable, but they aren't sealing well

With the new ones on, carbs just slip in no rubber grease required and you can actually feel the clamps doing something!

I also have the 22.5 pilots in for next time as well and have turned the mixture screws out 2 turns.

 

[Hoosier Daddy]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

If I can't muscle my airbox on, I guess I will need to spurge on a set. New boots with soft rubber are very tempting! I know I should go search it out on my own, but please explain the zip ties in the sparkplug hole. Are they holding up the valve? If so, that would be handy for replaceing valve seals as well.

 

[Big R]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

Pete, for those head bolts I just spray some engine paint (or whatever paint you want) into a rattle can lid and get some hobby paint brushes like what they use for model airplanes.

 

[hillsy]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

If I can't muscle my airbox on, I guess I will need to spurge on a set. New boots with soft rubber are very tempting! I know I should go search it out on my own, but please explain the zip ties in the sparkplug hole. Are they holding up the valve? If so, that would be handy for replaceing valve seals as well.

The zip-ties sit between the open valve and the seat - allowing enough space to lift out the shim and replace (only for shim on bucket types, not bucket over shim). You can't use this method to help replave your valve stem seals (if that's what you mean) because you need to remove the valve springs to get at them - which means removing the head.

If your airbox rubbers are stiff, hit them with a heat gun to soften them up. It won't last forever, but they will be soft enough for long enough to allow you to get the airbox back on quite easily.

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

If I can't muscle my airbox on, I guess I will need to spurge on a set. New boots with soft rubber are very tempting! I know I should go search it out on my own, but please explain the zip ties in the sparkplug hole. Are they holding up the valve? If so, that would be handy for replaceing valve seals as well.

Yeah do it, if your boots are old then seriously you won't regret it. I've read all the threads on the GSR saying change them and everything and I kept thinking no these feel soft enough, and then I had to order the fuel tap so I looked and for $25.01 each why not... sooooooo glad I did! Also, these are the carb to cylinder head boots, not the air box to carb boots... so that won't help you on the air box side...


Hillsy does a good explanation of the cable/zip tie, and as he says, definitely a no go for valve seals, only good for shims if you have them...

Pete, for those head bolts I just spray some engine paint (or whatever paint you want) into a rattle can lid and get some hobby paint brushes like what they use for model airplanes.

That's not a bad idea Rich! I'd like them polished up to go with the SS allen head case cover bolts though as the nuts are actually chromed. I've managed to polish up the fork cap bolts and the shock cap bolts successfully which are all chrome, so hopefully I can do the same for these.

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The zip-ties sit between the open valve and the seat - allowing enough space to lift out the shim and replace (only for shim on bucket types, not bucket over shim). You can't use this method to help replave your valve stem seals (if that's what you mean) because you need to remove the valve springs to get at them - which means removing the head.

If your airbox rubbers are stiff, hit them with a heat gun to soften them up. It won't last forever, but they will be soft enough for long enough to allow you to get the airbox back on quite easily.

Yeah what Hillsy said

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

Oh, and shim is here and in:

New clearance 0.05mm... sweet!


Valve cover back on, and man I really hope that oil burns off once I get it out for a ride, otherwise that Athena gasket is a goner...

And every time I see those head nuts... ugh...

 

[Hoosier Daddy]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

I do not know if it applies to your engine but on my GS750 the bronze tach gear is mounted in the valve cover and is driven off the forward cam shaft. Supposedly the Atena gasket is the wrong thickness and causes the gear to wear very quickly.
Like I said, may be apples to oranges but thought it worth mentioning...

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

I do not know if it applies to your engine but on my GS750 the bronze tach gear is mounted in the valve cover and is driven off the forward cam shaft. Supposedly the Atena gasket is the wrong thickness and causes the gear to wear very quickly.
Like I said, may be apples to oranges but thought it worth mentioning...

I thought it was the Real gaskets that were too thick? Could be wrong... either way nah my tach. gear's safe from that and is all in the head.

On another note I'm going to have to take a night off it tonight or tomorrow night and get my head around an accurate list of what remains.

I really need to focus if I'm gonna get her done this year and I need to make sure there will be $$$ available at the right times...

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

Turns out I've taken three nights off now, mainly because I've been feeling a bit like crap and tired, and I don't wanna work on it like that in case I lose concentration and screw it up royally.

On a positive note, I've done some eBay shopping for an R/R, mirrors, and wheel bearings, so I've at least done something...

 

[Hoosier Daddy]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

Must be something we have in common. We have both been hitting it pretty hard. Today all I did was go out and look at it... once.
WHOOPED!
But tomorrow is another day Bubba!

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

Must be something we have in common. We have both been hitting it pretty hard. Today all I did was go out and look at it... once.
WHOOPED!
But tomorrow is another day Bubba!

So true Hoosier! Usually I only take Saturday night off working on the bike, but had to take more of a break this time or I knew I'd be making myself sick. Three nights of or sick and who knows how long off... I know what I'd prefer!

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

I did duck down for a short time before the MotoGP started last night as I wanted to get at least one thing done.

So I got the front guard dropped the required 25mm.

Cut the brace/guard mount down 25mm's and drilled new mounting holes:

And it still seems to look ok. Ignore the dodgy pic's as I was rushing them trying to get back up in time for the race. And I only have two of the four mounting bolts on in these pic's too and not even finger tight, so it's not sitting quite straight:

And about 147mm clearance now:

So all I need to do with the front end now is work out how to route the tacho cable so it doesn't get pinned by the guard and neaten up the cuts and holes I did last night, oh and round the corners again.

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's ALIVE!! Dynatek Rocks!

Time for some little things...

Neglected to mention I did some eBay shopping the other day too for wheel bearings, mirrors, and an R/R.

Then last night I got the spacer for the Dynatek rotor sanded down so it's now spot on 0.125" and between that and the clean and lube it definitely feels a touch freer with the advance. No pic's as it's really hard to photograph the loss of 0.001"... :

And here's a not so dodgy pic front on of the lowered guard, and no it's not crooked, that's the flat front tyre off the bead that's crooked:

So, the other stuff I got onto last night was trying to make sure the front guard is ready for paint prep.

First I figured I no longer need to worry about re-routing the tacho cable as the lowered guard seems to stop the risk of it being pinched under full fork compression. Cool.

Then onto the brake line and speedo cables.

Mocked up the old brake line to work out if a new braided one can just be the same size, and it all seems to match up nicely with the new 'bars and Yamaha master cylinder from Mikes XS, so all good!

Dunno if you can tell but there's a little bracket that sits under the lower triple clamp to hold the brake line in place. I inverted that as being underneath will pinch the brake line under full compression of the forks:

Took the required measurements so I can order a braided line for it now.

Then onto the speedo cable and I want to use the cable guide from the stock guard which will stop it flapping about:

That mark is where to drill, except looking back at old pic's I think I need to move it back 1 to 1 1/2 inches to clear the brake line properly.

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's the little things...

So, the crappiness from the past few days... chest infection time, at least the beginnings of one... yay! Antibiotics time so will be all good...

Also need a new hot water system so Friday is screwed but scored tomorrow off as well so still all set to do the paint/foam hunt...

Anyway, a few more little things last night...

Definitely need to put the speedo cable guide further back:

Hole in the right spot, but needs to be enlarged a bit as it needs to be between two of my drill bit sizes:

Definitely a new headlight required:

Hopefully I can just replace the light itself and clean up the housing and mounting, need to take care of this crap though:

Need to see if some generic 7" light from an auto store has the right mounting to replace the guts:

And last but not least I've given up on the tiny lithium ion batteries as they're either too expensive for the good ones that have built in charging monitors (ie. $250+) or they don't have monitors built in and tend to explode when over charged... so I'm gonna head back to a standard style. Therefore the battery tray is back in and I can re-route the engine ground wire back to battery negative directly:

I do have some thoughts on making it look not-so-ugly in there but I shall keep those to myself at present

 

[Big R]

Re: 82 GS450E Scrambler from Aus - It's the little things...

Keep on plugging away at her Pete, you'll be rolling in no time. But don't over do it and make yourself sicker......

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's the little things...

Keep on plugging away at her Pete, you'll be rolling in no time. But don't over do it and make yourself sicker......

Cheers Rich, didn't even enter the garage tonight, I'm gonna crash in a minute instead to make sure I get plenty of rest.


Tomorrow is paint and seat foam shopping ;D

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's the little things...

Well I had a nice tour of the northern suburbs of Brissie today to pick up supplies.


Came back with this lot:

Primer and paint, 1mm sheet of alu. (not disclosing the use for this yet), exhaust wrap to use as a sheath for the Dynatek and oil pressure switch wiring (couldn't find anything better), rear footpegs off a Kawasaki EL250, and some neoprene to make the tank knee pads.


I also ordered some foam for the seat but that won't be ready until probably next Tuesday.


I then got a little spare time so I enlarged the hole on the front guard to fit the speedo cable guide:

Then I removed it so I could prep. it for paint later on.


Put the pegs on temporarily and the left one seems to sag a bit, but they held my weight when standing on them so they should be good. My wife's about half my size...

All the paint and primer in a bit more detail:

I figured I'd best make sure the seat latch sits in the tail piece with the rubber grommet properly so it's ready to putty and prep. for paint:

Just like the factory one...


So I should be good now to do the putty Saturday week and then get the painting done on my week off.

 

[peteGSX]

Re: 82 GS450E Scrambler from Aus - It's the little things...

So I got 1K primer yesterday but I need 2K primer... took it back for a refund and $62 later I have 1 litre of 2K primer


Man that hurts, it was dearer than the paint!!!


Also got some more masking tape, putty applicators, and a sanding block... at least they threw the 2K thinners in for free I s'pose...

Still need to get some masking paper and paint strainers, completely forgot them today...

 

[Hoosier Daddy]

Re: 82 GS450E Scrambler from Aus - It's the little things...

Glad you are feeling better!
Yes, Pro-paint supplies are expensive but the quality is top notch. I can hardly wait to see how this one comes out!