'80 450l questions

[backbiter]

Hello everyone I'm new to the site (and motorcycles really) and bought a 1980 450l the other day for real cheap. Here's why:

The previous owner broke the chain and it caught up behind that clutch cover(not too familiar with the actual name of it) and bent the clutch push rod and of course I have to replace the oil seal as well.

I've already ordered and received the parts from alpha sports but I'm kinda worried they sent me the wrong push rod. I received the 2 piece one from alpha but when I try to pull the old one out it comes out about 1/4-1/2 an inch then stops. Am I missing something?

Also, when trying to take the right engine cover off I stripped the bolts(like a dummy) because I just couldn't wait for the impact tool. Is there some sort of pack for these or do I have to order them 1 by 1?

[Nessism]

Z1 Enterprises sells stainless engine bolt kits. Nice quality and reasonably priced.

Clutch pushrod pulls out from clutch side. I suggest ordering new clutch springs and a gasket for when you pull off the clutch cover.

Part Shark is way cheaper for parts than Alpha-Sports.

Good luck and welcome!

[Flaming Chainsaws]

Welcome to the forum.

It's cool seeing someone with the exact same bike. I have only seen like 3 other people on this forum with a 1980 GS450L. Unfortunately I am of no help as I haven't torn into the engine yet . But the good news is that all GS450's have the same engine. Pete is rebuilding his GS450 engine. Maybe he knows?

http://www.thegsresources.com/_forum/showthread.php?t=158670

[backbiter]

Thanks for the replies guys. Is there a difference between the 2 piece and the 1 piece push rod? Well what I mean is are they compatible either way?

As soon as I move(next few weeks) I'll be tearing down my engine, replacing gaskets, springs, bolts, liquids, filters, adding a fuel filter, maybe cut my exhaust, tune carbs, and probably take some rust off while I'm at it

[pete]

Welcome to the forum! Good to see another 450 coming along.

From what I can tell, there's no difference in whether you have the single push rod or the two part one except that it's a whole lot easier to replace the pushrod oil seal with the two part one as you only need to remove the left side of the push rod and you can pull it straight out the oil seal.

I have the two part oil seal and I also have the non-flange type seal with the retainer bracket. The flange type seal without the retainer looks like it would be a royal PITA to replace. If you have that type now and are going to replace it, see if you have appropriate holes in your crankcase to be able to swap to the non-flange type with the retainer bracket. Getting the bracket could be interesting if they're not available from Suzuki, but I think in the long run it would be worth the trouble.

So, with the single pushrod, like Ed says you will need to remove the clutch to remove the pushrod and you should then be able to remove the seal.

I've also seen mentioned somewhere it's possible to drill a small hole, thread in a self tapping screw, and pull the seal out without removing the pushrod, but if the pushrod is bent you're going to have to remove the clutch anyway.

Also, do what Ed suggests with the stainless allen head bolts for the covers. I've just sorted mine out so they're ready when I've got my case covers all polished up and they will be so much better than the dodgy philips ones. Oh, and don't forget to use some anti sieze on them.

I also ended up getting my rings from a dealer in the US called Boulevard Suzuki and they had even better prices on the rings than Part Shark and they shipped them over here for me for a quite a reasonable postage cost.

Good luck and keep us up to date with progress!

PS you can see how the retainer sits in post #279 of my rebuild thread, link is in my signature below.

[pete]

Oh, and just reread your last post... don't add a fuel filter!

Lots of posts on here regarding adding fuel filters and most are too restrictive to let the vacuum do its job to feed the carbs.

There's a filter already in the fuel tap (you guys call it a petcock, we call a petcock a friendly rooster).

[Suzuki_Don]

If the pushrod is bent BAD you may have to cut the end off it before it can be withdrawn from the other side of the motor.

[pete]

Good call Don, seeing as it goes straight through the middle of one of the gearbox shafts...

[Suzuki_Don]

Good call Don, seeing as it goes straight through the middle of one of the gearbox shafts...

That would be the countershaft as the other shaft with the sprocket is the driveshaft. Being a bit technical, sorry.

[BassCliff]

Hi Mr. backbiter,

Merry Christmas to you. You'll find lots of GS lovin' here and on my little website. Let me spread some cheer!...

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", the Carb Rebuild Series, and the Stator Papers. Now let me roll out the welcome mat for you...

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[snark]

Welcome! Now here is the next big question...

What part of the world do you live in? One of us maylive nearby with spare parts or an extra hand to help.

...and then there is always finding people to ride with once she's up and running...

[pete]

That would be the countershaft as the other shaft with the sprocket is the driveshaft. Being a bit technical, sorry.

Spot on Don! I couldn't remember which one it went through at the time...

[mike10]

That was funny

Oh, and just reread your last post... don't add a fuel filter!

Lots of posts on here regarding adding fuel filters and most are too restrictive to let the vacuum do its job to feed the carbs.

There's a filter already in the fuel tap (you guys call it a petcock, we call a petcock a friendly rooster).

A petcock, Friendly Rooster. I nearly spit coffee on my keyboard. That's Funny!

[pete]

Haha glad someone got some enjoyment out of it

[backbiter]

Welcome! Now here is the next big question...

What part of the world do you live in? One of us maylive nearby with spare parts or an extra hand to help.

...and then there is always finding people to ride with once she's up and running...

near Houston Tx


No news yet about anything. work has moved me to 6-10s so I have limited time to do anything.(I'm STILL moving stuff!)

Did just order the stainless bolts from z1 though