1982 GS450t cafe

[Poopwink]

Hey all. I recently bought an '82 GS450t for $800 and am using the rest of the winter months to bring it up to speed and get it looking a little less tired.

The night I picked her up, hauled her 3 hrs back through fog and frost

Front end and seat work commenced. Have removed faulty ignition, removed and polished forks, polished front wheel, and removed the god-awful front turn signals and headlamp.


Next step is to figure out a replacement/solution because the lock cylinder is worthless. I think I may just be hiding a toggle switch on the frame somewhere and using that rather than a key to complete the circuit.

Also need to get new turn signals, new headlamp, and clip-on bars. Does anyone know the stock fork diameter of a 450 off the top of their head? I don't have a micrometer handy, and don't know what size clip-ons to order.

 

[lemmon95gt]

should be 37mm I made a set for mine and thats the measurement i had. I have a 850GL

 

[Guest]

Welcome to the forums! I'm a bit of a fan of the twins so keen to follow your progress!

Not sure of the fork diameter off the top of my head, would have to go measure...

 

[Redneck]

If you have had Basscliff's Megawelcome look up the service manual link he has. I know that they have more information in that book than you could ever think about. I am pretty sure they had the fork diameter for my 550 in there.

Paul

 

[Poopwink]

It's 33mm. Apparently the GS500's had 37mm forks but the 450s were running 33s. DoTheTon fork size guide

I used a crappy caliper set and it read out below 35mm so I'm pretty sure that's the case.

Just ordered some clip-ons, a smaller, more tasteful set of turn signals, and one of those EMGO ignition switches. I saw pretty good reviews for the EMGO ignitions so hopefully a brand new one doesn't crap out on me.

 

[Guest]

Cool, glad you found it!

I'm sure the Emgo switch will be fine, just don't use the Emgo pod air filters... they have a reputation...

 

[Hornswaggle]

Welcome to the forum and nice bike!

 

[Poopwink]

just don't use the Emgo pod air filters... they have a reputation...

I think I'd probably go with some K&Ns. That airbox just seems absurd to me...it's sooo big, and seems like such a clumsily designed system. When I get rid of that, I'll try and move that electrical nonsense into the space below the seatpan.

 

[Poopwink]

Pulled the exhaust. Boy is this thing haggard.

Chopped the mufflers. I thought there were going to be slip-ons but these had been welded and covered with some really cheap chrome panels.


I'm definitely going to have to mess with the carbs. I'm at almost 6,000 feet, so they need to be adjusted for that. I'm also considering running this thing without mufflers. Anything to keep in mind? Is the compression just going to be laughable if I do that? New jets are probably in order, huh? This is one area I don't really know a ton about.

 

[Englishman]

Welcome. Looks like you have a good bike to start the project. Suggest you don't run without mufflers. While you see plenty of bikes run this way, you have a time bomb that will burn valves sooner or later. There are plenty of low cost, less restrictive mufflers available. Either way you wil be re-jetting.

Mark

 

[Guest]

Yeah don't do the no muffler thing... aside from the lean running it will sound like crap...

K&N's are good and you'll definitely be rejetting like Mark said, and high altitude will also affect that.

If I remember right, high altitude means you run lean, so that's even more reason to get some mufflers on there...

As for the airbox, it's actually designed very well I believe, but on our 450's it's an absolute nightmare to remove and install. 90% of the reason I went with K&N pods on mine was to avoid having to install that airbox ever again...

 

[AFRetired]

IF you start thinking about painting that tank, PM me first. I'll swap you mine with a few paint blemishes, and save that nice original blue paint job of yours.

 

[Poopwink]

IF you start thinking about painting that tank, PM me first.

No plans to mess with the tank right now. It's got 3-4 small dings in it, but other than that, I like the OG color scheme.

I've started looking around, trying to find some exhaust solutions. Is anybody manufacturing 2-to-1 headers for this bike? I can't seem to turn anything up.

 

[Guest]

No plans to mess with the tank right now. It's got 3-4 small dings in it, but other than that, I like the OG color scheme.

I've started looking around, trying to find some exhaust solutions. Is anybody manufacturing 2-to-1 headers for this bike? I can't seem to turn anything up.

There should be a Mac around for that, I believe maybe Dennis Kirk or JC Whitney? Not real sure...

I think there was a Kerker at some point too, and the other is Motad which is a UK made version.

 

[lmrmllr89]

Yes Mac does make a two into one system......you can find them on eBay or at old bike barn.com for sure......I've got one on my bike...

 

[Poopwink]

Did a little more wrenching tonight, made a little more progress while waiting for front-end parts to arrive.

Got the airbox out of there...will you look at that filter! Disgusting.

The standard setup...

A little cosmetic surgery...

Quick mock-up of the cafe style seat I'd like to have on there.

Need to make a different battery mount now that I've freed up all that space below the seat. Also need to finalize the seat design and what I'll be doing for rear signals.

I can't find the MAC 2-to-1 header set for this bike for less than $260, I think I'll just be doing something on my own. This is a budget build, after all!

 

[Poopwink]

Got the new ignition switch in yesterday, and found what will be my taillight. The clip-ons and turn signals should be getting here tomorrow. C'mon c'mon! Just want to bail from work and get filthy in the garage.

 

[Guest]

Got the new ignition switch in yesterday, and found what will be my taillight. The clip-ons and turn signals should be getting here tomorrow. C'mon c'mon! Just want to bail from work and get filthy in the garage.

Yeah I know that feeling! I used to get that when I was in the middle of something during the rebuild, and now she's on the road I sit in the office looking at blue skys thinking I just wanna get out and ride!

 

[Poopwink]

Currently trying to determine what I need for my air filters. I've got (theoretically) 34mm Mikuni carbs.

I know to stay away from EMGO's pod filters, are there any other brands I should steer clear of? I figured it would be a piece of cake to get some matching pods but it's taking a little more research than I expected.

 

[Guest]

Currently trying to determine what I need for my air filters. I've got (theoretically) 34mm Mikuni carbs.

I know to stay away from EMGO's pod filters, are there any other brands I should steer clear of? I figured it would be a piece of cake to get some matching pods but it's taking a little more research than I expected.

K&N or APE are the go for quality pods. K&N have an application list that tell you what you need (I can't remember the model now but I have them), not sure about APE.