1980 Suz GS450E Project

[Guest]

Glad you got it sorted, I was going to say they're notorious for it.

I had my bike parked out the front of my work in about '99 when it happened, and I had to take the mechanism off so a mate could take it away and get it lubed with some graphite, seems to still work ok now but I'm not sure I'd risk it again.

 

[Strycker]

Ok so I've been cleaning the carbs today and want to install my o-ring kit from the Cycle O-Rings and I can't figure out which one is the needle jet. even looking through all the tutorials and all. Also, the adjustment screws.. are those under the brass cap in the fuel bowl area? If so how important is it to get that out to install a new o-ring? Becoming frustrated. That and after cleaning the carbs with Super Clean, I have white residue on the parts.. ugh..

Any help appreciated..

 

[Guest]

Ok so I've been cleaning the carbs today and want to install my o-ring kit from the Cycle O-Rings and I can't figure out which one is the needle jet. even looking through all the tutorials and all. Also, the adjustment screws.. are those under the brass cap in the fuel bowl area? If so how important is it to get that out to install a new o-ring? Becoming frustrated. That and after cleaning the carbs with Super Clean, I have white residue on the parts.. ugh..

Any help appreciated..

Ok, first things first... the mixture screws should've been out for the dip so the cleaner can get in those passages.

If you're having trouble locating them, FC's 450 carb rebuild guide should show you how to get them out.

On my Aussie model they're exposed so I didn't have to do anything to get to them.

They're not near the float bowls, they're on the carb body near the throttle shaft.

This is the best pic I have and you can just see it there (brass coloured flat head recessed in) right in front of my index finger like I'm pointing to it:

As to which jet/screw is which, left to right below is mixture screw, main jet, pilot jet, needle jet:

Not sure on what the deal is with the residue from the Super Clean (not sure what that is actually), but I used Yamaha's Yamalube carb cleaner and they were perfect afterwards, no residue or anything. Gave everything a really good rinse with the hose followed by compressed air through every passage followed by carb cleaner sprayed through every passage and then compressed air again to finish.

 

[Strycker]

Thanks for the images.. I have 3 of the 4 identified.. the one by your finger is the one i didn't remove. Wasn't sure what it was at the time. The carb guide i was looking at on Basscliff's site looked a little different and was throwing me off.

As for the residue I thing I left the parts in the cleaner too long.. oh well. I'll just try to clean it up as best I can. Should I have used a petroleum based cleaner and not a water based? Almost identical ingredients between the two I saw, but I went with the cheaper one. Live and learn. Figure it'll still work. SuperClean brands is what its called.

EDIT: and upon trying to get the screws out, they won't back out completely. They stop inside the tube and won't come out. Is there a trick to getting them out of there?

 

[Guest]

Thanks for the images.. I have 3 of the 4 identified.. the one by your finger is the one i didn't remove. Wasn't sure what it was at the time. The carb guide i was looking at on Basscliff's site looked a little different and was throwing me off.

I get ya', you were probably going off the 4 cylinder carb clean rather than Flaming Chainsaws 450 one.

While the 4 cyl. one is great and is the original (and has been recently updated I believe), FC's 450 one is specific to our carb's and should clarify these things for you.

As for the residue I thing I left the parts in the cleaner too long.. oh well. I'll just try to clean it up as best I can. Should I have used a petroleum based cleaner and not a water based? Almost identical ingredients between the two I saw, but I went with the cheaper one. Live and learn. Figure it'll still work. SuperClean brands is what its called.

I'm sure I've heard of some other cleaner or process doing the same thing, and I think it may be a minor reaction with the alloy but I won't swear to it, so probably do some more searching. I don't think it will do any harm though.

For the moment, maybe an extra rinse and blow through might help?

EDIT: and upon trying to get the screws out, they won't back out completely. They stop inside the tube and won't come out. Is there a trick to getting them out of there?

The O rings will stop them coming out completely as the thread stops before they come out of the hole.

I used a pair of flat blade jewellers screwdrivers to gently "walk" it out with one on each side, if that makes sense.

 

[Strycker]

Surely do appreciate all your tips. Found the guide by Flaming Chainsaw and that's exactly what I needed. I also decided to do things right and grabbed a can of Berryman's at the local autoparts store. Going to re-dip the parts to get rid of the residue. First set already in the dip and looks better already. Chalk that up to lessons learned. Get the right stuff the first time! I'll try to get some pics up of the progress soon. Been a while since I did much to the moto.

 

[Flaming Chainsaws]

Surely do appreciate all your tips. Found the guide by Flaming Chainsaw and that's exactly what I needed. I also decided to do things right and grabbed a can of Berryman's at the local autoparts store. Going to re-dip the parts to get rid of the residue. First set already in the dip and looks better already. Chalk that up to lessons learned. Get the right stuff the first time! I'll try to get some pics up of the progress soon. Been a while since I did much to the moto.

Glad you found my guide useful. I went back and reread my guide and it's kinda vague in some places. I have another set of GS450 carbs so I think I'll redo the whole guide with detailed pics, info, and the process.

Good luck on the rebuild!

 

[Guest]

I reckon your guide's good as is FC, certainly helped me out! So thanks again

 

[Guest]

Surely do appreciate all your tips. Found the guide by Flaming Chainsaw and that's exactly what I needed. I also decided to do things right and grabbed a can of Berryman's at the local autoparts store. Going to re-dip the parts to get rid of the residue. First set already in the dip and looks better already. Chalk that up to lessons learned. Get the right stuff the first time! I'll try to get some pics up of the progress soon. Been a while since I did much to the moto.

Good stuff, hopefully that'll get 'em cleaned right up and you'll be all set again.

 

[Strycker]

Okay, finally a few pics of the bike progress... slow and steady. Kind of get an idea of the paint scheme I'm going for in this. Still deciding what to do with the speedo and tach. They're all painted up but I hate the bulkiness of the housing. Their surrounds are damaged a little, so using them without really won't work. But anyways, here she is so far...

 

[Flaming Chainsaws]

I think stainless steel allen cap bolts will look very nice on the engine.

 

[Strycker]

I think stainless steel allen cap bolts will look very nice on the engine.

I agree they would, but at 3x the cost at the hardware store, I went with the stealth look and got the black head ones instead.

Still need to get the carbs put back together. The white residue is still an issue even with the Berryman's dip. Not sure what is causing that, but I'll make do with it. Ordered 2 bowl gaskets today from the local shop. O-rings are at ready to install, so that project should be done soon.

Anyone know a good place for a new brake line to the front caliper? The shop told me they are a discontinued item.

 

[Guest]

I think stainless steel allen cap bolts will look very nice on the engine.

+1, Z1 enterprises sell a kit for our 450's dirt cheap and you don't have to fiddle around as all the necessary bolts are there.

On that paint job, it will be well worth it

$24.95 plus shipping, everything there you need and all you gotta do is sort them:

http://www.z1enterprises.com/Bolt-S...SX-EZ-8082--Stainless-Steel-Set-702-1156.aspx

Can't go wrong!

I like the paint job so far too, very original but should look great.

Glad to hear the carbs are coming along well, maybe you need to soda blast the carbs or something to get that stuff off? I suspect maybe the cleaner has reacted to the alloy though which may have stained them...

As to the brake line, go braided steel line. Some people make their own (there are instructions on BassCliff's site somewhere) or you can get them from a couple of sellers on eBay for very good prices. I believe they're from Canada and are DOT approved etc.

I definitely wouldn't be replacing it with another rubber hose...

 

[Strycker]

Okay.. So looks like its been a YEAR since I was on here. Have made little progress so far.. It's all back together, frame and engine painted, wiring harness all check and re-wrapped. Installed a battery and get power to the lights, turn signals work but would like to upgrade to smaller lights and new relay. Bought some, just need to work on how to wire them since the old ones are grounded to the frame.

One another note, does anyone have a clue what my bike is ? I don't know if it's an E, L, S or ESX or any of the others. I need a new clutch cable and don't know which style to buy. May as well get a new throttle cable too while I'm at it.

Tested the coils resistance. I get 22.1k from one and 20.9k from the other on the ohmmeter. Seems within correct spec. I've got to diagnose the starter system. May need a new solenoid as the positive terminal seems loose. It definitely moves. Probably shouldn't do that. When purchased, the guy said he was going to rebuild the starter. Is that a simple task to undertake? Or is it advisable to just buy another?

Lots of tinkering to do still, but excited that the lights lit up after 30 years. Any suggestions would be appreciated. Post up some pics soon.

 

[SVSooke]

One another note, does anyone have a clue what my bike is ? I don't know if it's an E, L, S or ESX or any of the others. I need a new clutch cable and don't know which style to buy. May as well get a new throttle cable too while I'm at it.

This one's easy,a 80 or 81 GS450E.Tank,covers and tail give it away.

 

[Guest]

+1 on the stainless Allen head bolts. They would really contrast against the black. I love the white too. Just something about white done right is awesome. I love Gatekeepers paint job. You should check it out. My build is about like yours. I'm almost a year into t and have yet to fire it up but I'm getting anxiously close. Keep plugging away!

 

[Strycker]

This one's easy,a 80 or 81 GS450E.Tank,covers and tail give it away.

Thanks for that. I've been looking for one that is complete and original that says for sure, but never came across one. I need to get those cables ordered so I can get the clutch working to make sure it's working. ProMotion cables has some available on Amazon, just needed to get the correct one.