My new GS450

[Flaming Chainsaws]

I disassembled both carbs today and it went almost smoothly. I have two issues I need some advice on:

1.) I broke the main jet on one of the carbs trying to remove it. I wasn't patient enough and didn't use enough cleaner/penetrating. The slot is formed by two "half-moons" and one of them sheered off completely leaving nothing to grab.

I'm going to buy some extractor screws (left-hand, self-tapping) and lots of penetrating oil to get it out. CRC2 has the jets. A spreadsheet I found says it's a 115. Can someone confirm this? Any tips on removing the broken jet?

2.) I drilled out the plug covering the idle mixture adjustment (I think that's what it is) and it unscrews fine but I can't get it out. I run out of threads and the screw is still 2-3 mm deep in the bore. I can feel is clicking over the end of the threads so something, I assume the o-ring, is holding it back. With the o-ring in place I can't dip the carbs until it's removed. Do any of you know how I can get it out?

By the way, the technique I used to remove the plug: drill down with a bit 1mm smaller than the bore. Then I pressed the "ring" out by backing out the screw. This left the bore very smooth instead of hacked up by my drill bit.

Maybe you have seen it. Maybe not. I wrote a GS450 carb rebuild guide which is now on BassCliff's website.

http://members.dslextreme.com/users/bikecliff/

It really doesn't matter if you're dipping the o-rings. You should have brand new o-rings anyways. But to get that adjustment screw out, spray some PB Blaster, let it sit, then try again. If it doesn't work, just knock the carb on your hand or something and it should fall out.

EDIT:
Buy the o-rings here. Robert Barr is a forum member here and has sold thousands of these kits with happy customers, including me

Get the GS450 combo kit.
http://cycleorings.com/450.html

 

[agranner]

Thanks FC, I'm following your article which is great. I've also ordered the o-rings from Robert Barr but haven't received them yet, I've got time to figure this out.

So, I can just "knock" the screw's out? I'll let them soak for a while with PBB first and let you know.

 

[Flaming Chainsaws]

Thanks FC, I'm following your article which is great. I've also ordered the o-rings from Robert Barr but haven't received them yet, I've got time to figure this out.

So, I can just "knock" the screw's out? I'll let them soak for a while with PBB first and let you know.

Yeah, it worked for me lol. I was getting ****ed that it wasn't coming out so I just knocked it on my hand a few times and out it came. When it does come out make sure you don't lose the little spring.

 

[agranner]

Carb work continues

Carb work continues

I've been working on my carbs and it's been going pretty well. Got them apart, dipped, and half put back together.

O-rings came and seem to work great. I used blue (medium) threadlock on all the screws that go into castings, ie. piston chamber top, float bowl, and choke assembly. I used assembly lube on all other threads and o-rings. The floats were getting a little crusty so I scrubbed them with carb cleaner and wiped WD-40 so I hope they don't "rust" before I get gas in them.

I did ruin a main jet, but I got it extracted fine. I ordered replacements from CRC2 but they did not send the right ones. The jet I did not ruin says clearly: "115" and two Japanese characters. The replacements clearly say: "110" and "AB". They also have clearly larger orifices, and I would have noticed none of this except they don't fit at all. The "screw head" portion is way too big since the hole in the float bowl is right next the to threads for the drain plug. I am thankful they didn't fit.

So, CRC2 messed up and sent me the wrong parts. They also shorted me one oil filter (I ordered two). They will hear from me tomorrow when they open at noon in Indy.

Otherwise, very easy. I think I mis-counted the idle mixture screw turns because 3.0 turns out seems unusual (I forgot to count the first one, but I remembered the next time). I will set it to 2.0 and plan on having to mess with it once the engine is running.

In other news: I ordered key blanks from motorcyclekeys.com and found a shop to cut them to the codes I found all over the bike. I ordered the blanks thinking no one would have them local but that was unnecessary. They are generic keys, not Suzuki.

AND...

I got some info on getting a bonded title. Pretty simple: I just get an appraisal and turn it in with my application, bill-of-sale, title fee ($95), sales tax, and a 3-year bond in the amount of....

150% OF THE APPRAISED VALUE!!!

yikes. Hopefully, I can get a good appraisal. This is all getting very expensive (compared to the price of the motorcycle).

More updates to come. I'm going back out to work on it in two weeks since there is no longer a football game worth watching

 

[agranner]

Just called CRC2 and I'm so glad I did. Even though these are Mikuni carbs, standard Mikuni jets DON'T FIT!

I just happened to mention the fit of the incorrect jets they sent me, and the guy was like, "wait a minute." Apparently, since the jet screws into the float bowl and not the emulsion tube, I need a special Mikuni jet with a small head. Or I can just use Keihin jets since the threads are the same but they have a small head.

I love working with people who know stuff. Makes my life a lot easier.