(Part 3) Top products from r/CafeRacers

These 60s bikes always had the coolest road-racing styling, and then just the crappiest bars known. With no good mounting points for rear-sets, and no good mounts for clip-ons, you'll have a tough time being comfortable with clubmans!

Check these bars out:
https://www.amazon.com/gp/product/B0050HC3LW/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

I've started putting them on everything.

They correct the weird stance of the 60s bars, but keep you comfy while your feet are on the pegs.

Also, for these older small Italian bikes, moped sources are where it's at. If you're stateside, Treatland.tv has tires and tubes that will fit those small rims, electrical parts for days, cables, knarps, and all that jazz. And don't just search for "Cimatti" in your ebay parts search; I've found all the Italians shared parts: Moto Guzzi, Aermacchi, Cimatti, etc.

Your greatest challenge will be if the piston and/or cylinder are scored. If it spins free with good compression, and a good flashlight check, you could have this thing running in two weeks.


EDIT: I almost forgot! This old single-stage paint fucking ROCKS. Hit it with some buffing compound, and it comes alive. That black and silver Aermacchi in my pic used to look just like yours (note the hazy forks, not yet buffed). With some proper compound, pads, and wax, it looks so good. If you can buff that out without killing the pinstripes, it'll be the shit.

I HAVE THE SAME BIKE!
Mine is a GS450TX


TL;DR = fix bike fairly quickly and just ride :)


I hope this helps.

(INCOMING WALL OF TEXT!)

2 years ago I cut my mufflers off and mounted Emgo Shorty's. I also replaced my air box with Uni foam pods. I re-jetted the pilot from 17.5 to 20. I moved the main jet up from 115 to 122.5. I briefly cleaned the carbs with the spray parts cleaner, set the air mixture screws to 3 turns, and reassembled the bike. It ran like crap because I took so many shortcuts. I spent a couple weeks riding and fighting with the bike then I parked it for winter. 2 years went by and I didn't even want to deal with the crappy state my bike was in so I left it parked until we moved (better school zone for kids).

Once we got settled I brought my bike home and started tearing it down.
I spent a couple weeks doing the following:

• Downloaded manual = https://skydrive.live.com/redir?resid=2370B62DDF9F0C6B%211334&authkey=%21APM7hx6Q2ynLu-A
  
  
  
• Properly cleaned the carbs (soaking them for 12 hours in original Pine Sol (50/50 mix with water) cleaned them better than any other parts cleaner I've used in the past). All of the rubber on the carbs were in excellent shape, so I lucked out there. Rinse with mild soapy water then hit each part for 1 minute with toothbrush. Rinse with water and reassemble. Adjust air mixture screws to 2 turns out.
  
  Bench-sync slide/butterfly valves PDF Guide = http://members.dslextreme.com/users/cbsaunders/gs/gs450_carb_cleaning_guide.pdf
  
  Parts = https://www.partzilla.com/catalog/suzuki/motorcycle/1982/gs450t/carburetor
  
  Rebuild = https://youtu.be/w16in05ANN4
  
  Soak = https://youtu.be/zDkOgnPidPs
  
  Bench-sync = https://youtu.be/AS77T2CUsjI
  
  
  
• Changed Jets to: pilot = 22.5 / main = 130
  http://www.jetsrus.com/a_jet_kit_street/suzuki_450_GS450S.html
  
  
  
• Carb boots + o-ring were still in good shape so I left them alone.
  Test boots for leaks = https://youtu.be/XzjSEYB9RDU
  
  
  *Modified Uni foam pods: 1) removed half of the inside lip with an knife so the air intake circuit wouldn't be partially obstructed 2) Temporarily restricted Uni pods by taping a ziplock bag around the sides and cutting the bag away from the back end so air intake would be smooth.
  
  
  
• Removed gas tank and filled it with a 50/50 mixture of distilled white vinegar & water for 24 hours (be sure to remove gas cap and petcock and tape closed). Drain mixture from petcock hole, take a picture of 1lb of rust chunks and post on Reddit for easy karma :) Fill tank 25% with water from garden hose and shake for 1 minute solid. Drain and repeat x10. Ok, last time add 1/2 cup of baking soda/powder to neutralize vinegar. Rinse clean.
  Clean tank = https://youtu.be/UpaGo_nq5Rk
  
  
  
• Test petcock vacuum before reinstalling. Suck in vacuum tube and plug with finger. Test Reserve, Fuel, and Prime settings. The latter should be the only one that allows air to flow without sucking on the vacuum tube. My petcock's diaphragm was ruptured so I replaced it. Pro Tip: don't by the cheap $20 replacement from Amazon. It is crap and constantly leaks fuel on all settings once fuel begins to flow... even when no hoses are attached. Find the OEM replacement for $45 and move on.
  
  
  
• Install new fuel/vacuum/vent hoses on carb. Also get a cheap kit from Amazon that has an inline fuel filter and cutoff valve. (This will make draining and carb maintenance easy) https://www.amazon.com/dp/B07MXH6Z7S/ref=cm_sw_r_cp_apa_i_tse1CbD0V0DY3
  
  
  
• Test battery charging system = https://youtu.be/njky7cNEdYU
  
  
  
• Change engine oil = https://youtu.be/Opqbbqfxmsk (use Lucas semi synthetic 10w-40 to aid with shifting due to wet clutch)
  
  https://www.amazon.com/dp/B001KWGA10?ref=ppx_pop_mob_ap_share
  
  
  
• Buy a Seal Mate (or make from plastic container) to fix fork seals if dirty = https://youtu.be/8wlzfoVroSY
  
  
  
• Change fork oil = https://youtu.be/81hWzXOAvww (use Lucas semi synthetic 10w if under 200lbs, and 15w if over 200lbs. Also, when you refill fork oil compress forks completely, with springs removed, and fill to 6 inches from top)
  https://www.amazon.com/dp/B0041CDW7G/ref=cm_sw_r_cp_apa_i_Pye1CbGHFE87B (buy locally at O'Reilly's cheaper)
  
  
  
• Change tires = https://youtu.be/D8MFXZr36hs
  (I found a great deal on Kenda Dual Sport K761's at http:/denniskirk.com Front = 100/90-19. Rear = 120/90-17.
  Tools needed = Spoons with 2 Rim Protectors https://www.amazon.com/dp/B079JZN5BC/ref=cm_sw_r_cp_apa_i_QEe1CbCMX9JBM
  Balance tires easy = E-Z Tire Beads Motorcycle Kit, Ceramic Balancing 2 oz Front + 2 oz Rear. https://www.amazon.com/dp/B00VOAOSDA/ref=cm_sw_r_cp_apa_i_hDe1Cb8QTNKYF
  
  
  Other notable links:
  
  The GS Resources = https://www.thegsresources.com/
  
  GS Forum = http://www.thegsresources.com/_forum/index.php
  
  Bike Cliff's site = http://members.dslextreme.com/users/bikecliff/
  
  Parts = https://www.babbittsonline.com/oemparts/l/suz/50d3f2caf8700230d8b4bf8c/1982-gs450tx-parts
  
  
  *** After all this maintenance, my bike starts easily, sounds incredible, shifts wonderfully, is very reliable, and a hell-of-a-lot of fun!
  
  
  ~Best of luck friend~

Just a lot of books... Here a re some of the ones I've bought over the past year:

Welding:Principles and Applications (this is a bit overkill but I found it at a used book store)

Advanced Custom Painting Techniques

Four Stroke Performance Tuning

Engine Builders Handbook This is more focused on V8s but has a lot of great advice/best practices.

Sheet Metal Fabrication I have only used the skills in this book to make my electronics box so far, I was originally going to make a cafe style seat but decided on room for a passenger. Someday I would like to make my own gas tank.

Other than that it's a lot of online research!

The good news is you have awesome carbs.

If you have the scratch, you might consider one of these:

http://www.amazon.com/gp/product/B004MDT8MW/ref=s9_simh_gw_p263_d5_i1?pf_rd_m=ATVPDKIKX0DER&pf_rd_s=center-7&pf_rd_r=1CHWYHHQHCSMFYQCT780&pf_rd_t=101&pf_rd_p=1688200482&pf_rd_i=507846

That is the absolute ultimate carb-tuning tool. It tells you absolutely whether you're rich or lean. You want an air/fuel ratio of 14.7:1 most of the time as 12.8:1 balls-out-wide-open. As you make mods to the pipe, carbs and/or air cleaner this will tell you exactly what's up. Even once you have everything straight you can leave it on as a diagnostics tool, or pull it and plug the sensor bung location with a screw.

We're not seeing this tech on bikes yet but...makes a ton of sense to me. I've wrestled with carb tuning for years and can't wait to build a bike with this baby.

Removed the original headlight mounts

Sanded down all the rust under the headlight mounts

Removed aftermarket drag bars

Installed clip-ons

Installed new levers

Bought custom length brake cable and banjo bolts (bought locally, no link)

Mounted headlight on new brackets

Made custom bracket for speedometer out of metal bought from Lowes

Bar end mirrors

Grips

Horn+turn signal+headlight switch

For some reason I can't remember where I got my throttle. It's kinda Gerry rigged together. So buy something you're comfortable with.

Edit: Feel free to contact me for details on the changes I've made. I'd be glad to share details where needed.

I've had good experience with Uni pods. Dip them in a bit of oil before installing and it'll give you a more favorable flow resistance. http://www.amazon.com/Uni-Pod-Filter-Kit-Chrome/dp/B000GZMZKC/ref=sr_1_10?s=automotive&ie=UTF8&qid=1417452486&sr=1-10&keywords=uni+filter

/u/BASE1530 nailed it. If you're looking for a chrome finish from a plain steel tank you're going to have a bad time. If it were that easy everyone would be doing it and as you've found, they are not. If the question is just the gas resistant clear coat that one is easily solved with a can of this.

Tach Here

Speedo Here

I may change speedo out, not sure. This one is fairly big, but I like the GPS part.

http://www.amazon.com/gp/product/B005FMTX4M/ref=oh_details_o03_s02_i00?ie=UTF8&psc=1

You definitely sacrifice visibility. At the same time I never rely on mirrors and these don't bother me because I always turn my head regardless.

Yeah, with proper padding and some cam action clamps, that would be a good move. Am looking at buying a couple of clamps like this, given the recurring problems I've had with this and similar jobs.

You could probably remove most of that branding with one of these guys. Might not work perfectly, though. In fact, it would probably look hideous. I'm curious if anyone's tried this, though.

Close up.

Stock intake plenum, ABS toilet plumbing (new), 70mm UNI filter.

Exactly this type of battery.

https://www.amazon.com/gp/aw/d/B002GTKAHQ/ref=mp_s_a_1_3?ie=UTF8&qid=1526871235&sr=8-3&pi=AC_SX236_SY340_QL65&keywords=bar+end+mirrors&dpPl=1&dpID=41E%2BMoq7dvL&ref=plSrch

Luster Lace