Help with a GS450 1982

[pete]

Great! I got the gasket ordered and been looking at some new controls for the bike. I think I will be ordering them from k&s, they got a few, simple looking, ones.

I am curious if anyone on here has put pods on a GS450?
I know there is alot of people don't like them, in performance...
Any suggestions beside K&N?
If so, what size jets did you install in your carbs?
Or is there a guide online I can look up?

Thanks again for all your help!

If you're going to go the pod path, definitely go K&N.

While I can't help you with jet sizes right now, I'm hoping to be able to soon. I want K&N's to go with my custom exhaust, all depending on my bike firing up after the rebuild.

The rule of thumb for good pod filters and a free flowing exhaust is up three sizes on the main jet and one size on the pilot.

That's what I'm intending to follow once I get the pods and exhaust, and of course from there on in it should be a matter of plug chops, hair pulling, and asking for lots of help on here

[WoodenPlanks]

Hi Mr. WoodenPlanks,

Wow, I don't think we have any other members in Hawaii. I'd love to ride out for a visit sometime.

I am happy to be the first! Thanks for such a warm welcome.

I visited your site, what a great resource. Having the manual downloaded will definitely help.

K&Ns looks nice, I was just hoping to find more variety and/or options.
Does anyone know what the jet sizes are stock in the carbs?

@pete, what kind/style of exhaust are you putting on there?

[pete]

I am happy to be the first! Thanks for such a warm welcome.

I visited your site, what a great resource. Having the manual downloaded will definitely help.

K&Ns looks nice, I was just hoping to find more variety and/or options.
Does anyone know what the jet sizes are stock in the carbs?

@pete, what kind/style of exhaust are you putting on there?

Firstly, with the manual from BassCliff's site, be real careful with torque spec's and such as I have already encountered one that is incorrect and now use the spec's from the Clymer only. I only refer to the Haynes for different views in diagrams now.

Try this link to see if your carbs are mentioned for the stock jet sizes (I haven't looked through it yet):

http://www.thegsresources.com/_forum/showthread.php?t=73723

As for my exhaust, I'm intending to go to a place here in Brissie called Tranzac to get them to make me a custom exhaust along the lines of the 2 to 1 Arrow aftermarket exhaust found on the Triumph Scrambler.

[BassCliff]

K&Ns looks nice, I was just hoping to find more variety and/or options.
Does anyone know what the jet sizes are stock in the carbs?

Hi,

Sorry, I haven't been able to locate a factory manual for the GS450. The Haynes is the only one I have available.

The K&N filters have the reputation of being the best with the APE parts a close second. The EMGO pod filters are trouble. There is not a lot of variety in the aftermarket for these old bikes.

As for stock jet sizes, look in the carb sections of my little website for the chart. There is also a 450 carb rebuild guide on my website. Keep us informed.

Thank you for your indulgence,

BassCliff

[pete]

Hope I didn't offend you with that post BassCliff, I certainly appreciate the fact that you host what you have

[snark]

Hi,

Sorry, I haven't been able to locate a factory manual for the GS450.
BassCliff

Lots on Ebay. I got one for about $20. Here's one for $25.

http://cgi.ebay.com/ebaymotors/suzuki-service-manual-1980-1988-gs450-gs-450-_W0QQcmdZViewItemQQhashZitem4aa7639e15QQitemZ320635903509QQptZMotorsQ5fManualsQ5fLiterature

[BassCliff]

Lots on Ebay. I got one for about $20. Here's one for $25.

http://cgi.ebay.com/ebaymotors/suzuk...sQ5fLiterature

Thanks, but I meant a digital version.


Thank you for your indulgence,

BassCliff

[WoodenPlanks]

Ok, so I started rebuilding the carb to soak them, with the help from your walk-through. (Thanks!) And the needle jet is stuck in the float bowl.
I am afraid I tried using pliers gently but ended up scarring it a little and it still wont come out.

Any tips?

[Nessism]

Ok, so I started rebuilding the carb to soak them, with the help from your walk-through. (Thanks!) And the needle jet is stuck in the float bowl.
I am afraid I tried using pliers gently but ended up scarring it a little and it still wont come out.

Any tips?

Good job on tackling the carbs properly.

In case you didn't know, cycleorings.com has a kit for the 450. I think they have the intake boot O-rings too (please don't skip these).

If that needle jet doesn't come loose after soaking, try hitting the carb body with a heat gun. Heat will melt the varnish holding the parts together. What ever you do don't force anything.

Good luck and keep going...

[WoodenPlanks]

Yeah that's was I was hoping for...
cycleorings is great, I am awaiting my order from the site and I'll rebuild these things right.

I will be changing my intake system to K&N and my exhaust will be a free flowing system. So, taking pete's advise I will order a main jet three sizes up from 115 to 130 and the pilot from 45 to 47.5? Is that correct??

[pete]

Good stuff, cycleorings is definitely worth while.

Don't just take my word on the jets, go here and read, this is where I got it from:

http://www.motorcyclecarbs.com/

You may find other more useful info therre too.

Are you still stuck on the needle jet? I got stuck on that too, but letting WD soak into over night was all it needed. I was able to grab it vertically with needle nose pliers and gently but firmly rotate it left to right and pull it out. I did get a couple of scratches on one where the pliers slipped at first, but just surface scratches, no damage at all.

[WoodenPlanks]

Great thanks for the resource, he has some good tips on there.
I decided to soak the float bowl with the needle jet stuck in it. hopefully it will break it free.
I have been looking everywhere for a replacement needle jet but can't figure out the style it is. The manual lists the size O-6 but no style number.

[WoodenPlanks]

Just an update:
I have been taking parts off, cleaning them up. Removed the headlight ears and replaced them with chrome ones. I have been looking at these 2 into 1 exhaust systems online. What do you think? Rejet? Again? haha...
Oh and by the way while taking off the exhaust, one of the bolts snapped...****. I have an extractor set but I am curious if you guys have any tips. I have been soaking it with WD40 for the last couple days hoping to free it up a bit.
Thanks again
-AJ

[pete]

Do some searching here and you will find tons of threads about broken off exhaust bolts.

A common permanent fix once they're removed is to put studs in instead of bolts.

Depending on the 2 into 1, it may not need rejetting as a lot (Motad is one I know for sure) are designed to be a direct replacement for the stock exhaust.

[Charlie G]

Do a search on removing that broken stud. I've read about using reverse drill bits being much better that extractors.

cg