1980 GS450 DRAMAs

[Green]

Hi Dudes.

First of all, great forum. I've read alot of cool stuff to help me with my bike...

But..I still have questions..so I'm looking for assistance.

The issue is that it looks like my bike needs a re-build. Problem is that I live in Australia and parts for this bike are extremely hard to come by, and when they do, they cost a fortune. So a bit on the bike.

1980 GS450e. Bought the bike for $1100 about 2 months ago. Bought it on the Saturday, it was running. On the Sunday...it stopped. I replaced the Battery ($60), took it to a mechanic to get it road-worthied (this is what we need to do before registering a vehicle) and it ended up costing $400+ for a new starter motor and to fit it. The bike still had horrible compression and was leaking oil.

After further diagnosis the mechanic advised that it would most likely need a top end rebuild..and it would cost less to get new, larger pistons and rings..boar the cylinders (plus some extras..new petcock etc)...quote $1200 (total = 1100+460+1200 = 2760).....BUT, this quote was based on being able to get the parts...AUSTRALIA = PARTLESS. Got a call yesterday and the parts are scarce, quote = $1800 (with Suzuki parts). So, I was thinking....this dude is busy, maybe I can see if I can source the parts and probably get them cheaper..NOPE..Checked EBAY (1 piston available), a bunch of stockists of OEM parts in the STATES and the UK...only to be told that the oversized Pistons and Rings I want have been discontinued...

So here I am, scouring the the forums for advice...I have found mention of fitting a GS500 engine in the frame, which I would then need to modify the already dodgy exhausts or get one made. or use a GR650 top end...which would be even more rare in Aus then the GS450.

I have, however read in no clear terms that maybe the cheaper answer is use the GS450 bottom end, find a GS500 Cylinder with pistons and use the GS450 head?

So I'm looking for the cheapest option I can find to get this bike working and running well.

Any advice would be great.

cheers.

[Sci85]

If it were me, I'd part it out and start over with something in much better condition and parts availability.

Good luck...

[tkent02]

Hmmm, wait a minute, why exactly does it need rebuilt? Won't run and leaks a little? Did he give you the sresults of the compression test? Did he do a leakdown test? Did he even determine why it isn't running?


Bad compression is usually because the valves are out of adjustment. Leaking oil means it needs a gasket replaced someplace. or maybe a few gaskets. All very easy, you can make most of the gaskets yourself even if you live in a partless land.

On the other hand if you part it out you can ask top dollar for each part in that partless land, you should do OK.

[Green]

Hey dudes,

Compression was about 100 in one, and 110 in the other. The Spark plugs were oily. I called a couple of local wreckers, and they laughed in my face when I asked about a replacement GS450 engine...ha....Any recommendations on fitting gs500 cylinders?

Thanks for replying guys, selling it for parts is not a bad idea.

[pete]

Hey mate, where in Aus are you? I really haven't had dramas getting bits for my 450 if I've needed them.

www.findapart.com.au may help you out a bit, otherwise www.mickhone.com.au for genuine parts at a good price from Melbourne.

www.suziparts.com.au in South Australia may have some discontinued parts but his prices aren't cheap. Also Tiaro Motorcycle Wreckers have a starter motor for $160 at the moment... I managed to repair mine thankfully.

I'd really be sus on why it was running and all of a sudden needs a rebuild... my limited experience with motorcycle dealers/mechanics is that most look at old bikes and just aren't interested. They bump the price to unrealistic levels because they really don't want to work on them.

I rebuilt my 450 completely myself with advice on the forum here after never having done more than an oil change and spark plug re-gap.

Almost 20,000km's later it's still my daily rider and weekend fun machine and 100% reliable.

Edit: Forgot to say that if I ever decide to do something a little more wild, I'd be going down the path of 500 barrels with the 450 head myself... search for posts by "Bwanna" on here as he has done this mod.

[Green]

Thanks Pete

Hi Pete,

Thanks a-plenty for the information, I'm in Brisbane...and I was scouring the internet a couple of days and didn't come across this site..Thanks HEAPS!

Even that this dude may not be able to help with the oversized pistons and rings, like the OEM dealer in the states. But we'll see.

Thanks again.

This forum is the BEST!

[Big Rich]

You would be amazed at what parts swap over from the 500 motor. Oil pump, Clutch basket, stator and R/r, etc.. The cylinder & pistons can be made to fit with a little research, but I would follow Tkent's advice first. A little tune up might save you hundreds (maybe thousands) of dollars in the long run.

[koolaid_kid]

Compression of 100 and 110 does not indicate that it needs an overbore. I suspect your mechanic is feeding you a line of bull.

[pete]

Whereabouts in Brissie? I'm in Keperra.

Depending on time and circumstances and where you are I might be able to come 'round and take a look as well.

Also, you're more than welcome to join us on our rides too, we have a big one once a quarter (see here: http://thegsresources.com/_forum/sho...d.php?t=203846) and there are also some guys who ride most Saturday mornings from Cashmere and I try to join them a couple of times a month.

Most of the regular riders are from Katana Australia but all air cooled GS(X) riders are welcome.

I'd also tend to agree on George's comment that 100 - 110 compression is more than likely serviceable...

[koolaid_kid]

While you are there pete, check for the source of his oil leaks. If it is the head gasket or base gasket, you know what to do.
Are gasket sets available in Oz?
Seals, rings, etc.?

[pete]

There is a source for the dodgy Athena gaskets here which I used... still ok for the non-critical gaskets to save some $$$ but genuine ones can be had still.

Should be the same deal for seals and rings.

One thing I do know unfortunately is that the official gasket set for the 450's cannot be found

[Green]

Hey guys,

Pete, I'm in morningside. Thanks for you help,dude. I've sent the information to the dudes doing e bike. It's not only get mechanical work done, but it's also under going a "brat style" make over. Once that's done, I might take you guys up on that ride you dudes do. I'll definitely remember to put some pics up too. I think it's going to be great when it's complete..

Cheers.

[pete]

Cool, Morningside's not too far away.

I didn't realise you had someone doing all the work for you... Is it one of the new places around like Ellaspede or PopBang or something?

Definitely join us for a ride! There's only about 3 on here that join us these days and 2 of those are on the Katana Australia forum as well, so would be good to get some more GS' out.

[Green]

Hey Pete,

It's at Ella, those dudes are good dudes. I decided to buy another engine and possibly sell the other part of the engine on the eBay, or possible have a go at rebuilding it myself. I've bought a 2009 gs500 engine (it was pretty cheap), the plan is to use the 450 head. Not sure about the carbs, from what I've read in one of "Bwanna's" post that the gs450 carbs should be okay, just needs new jets..or something. Do you have any thoughts about this? Carbs seem to be expensive.

The dudes are doing a good job. They've finished the front and my seat should be arriving this week to start on the back.

Cheers

[pete]

Cool, hopefully they get her all sorted for ya' and you have a great bike.

Their work looks good visually (saw some at the Laverda show last year I think) so hopefully they know their stuff mechanically as well.

Here's my thread on getting my carbs right and I'm about to update it shortly with what I did last night.

http://thegsresources.com/_forum/sho...d.php?t=207055

The GS450 carbs are probably ok but if you can get newer 500 carbs they're apparently much lighter... as long as you get the 450 ones tuned well they'll be fine though.