Waking up an old GS450

[gspaul]

Post a new topic for the diagram, I am shure someone can email it to you!

[Anonymous]

Try here: http://www.smokeriders.com/diagrams/ under suzuki four-strokes

[snark]

So now it runs with one dead cylinder...and the coil is fine. The two big problems now are that for some reason it will start without holding the clutch in and some if the wiring is so cut up there isn't any thing left to connect. Time for a new main wiring harness.

[snark]

Now to add to the soap opera...we thought one of the header bolts was among the may missing. It turns out that it is snapped off in the head. Does anybody know a way to get it out that will not invole tapping the hole and using an oversize bolt? There isn't an exhaust leak so I'm tempted to let it be, but part of me is saying that it should be repaired properly. Any suggestions?

[nabrams]

If there's no exhaust leak - JUST LEAVE IT ALONE. It may be that whatever remains of the bolt is digging in to clamp enough to hold it tight.
So unless you need to remove the exhaust there's no reason to mess with it.
I've had to do the drill-tap-helicoil routine on my friend's GS450 and it's a real pain.

[IanFrancisco]

Try here: http://www.smokeriders.com/diagrams/ under suzuki four-strokes

Wow, great link, Thanks!!

[snark]

Update:Got disgusted with the old harness so we replaced it. The right cylinder is still dead so I'm leaning toward a bad coil. Still no lights, a freind of mine is suggesting dirty contacts in the ignition switch for that. She cranks only when she wants to, clutch in or out--I thinking of a bad switch there. Any thoughts or suggestions as to whether or not I'm headed in the right direction?

[IanFrancisco]

You can bypass the clutch/starter interlock switch or whatever it's called. The two wires from the switch on the bars go into the headlight bucket and connect to the harness. Disconnect the switch and connect the two wires from the harness together. Remember to have the bike in neutral or clutch pulled in when you start it!

I would also clean the contacts in the starter button, the connections for the heavy wires going to the starter motor, and the connections to the starter relay (solenoid), which is the gizmo the heavy red wire from the battery is connected to.

[snark]

Can't bypass the clutch switch because of inspection regs. I'm going to try pulling the switch apart and cleaning it. The key switch part is what's bothering me. It makes sence that bad contacts could cause these problems, but it sounds too simple.

[bgmart450]

They do get gummy. I had to jump the S off the relay for a while until I actually pulled the starter switch apart and cleaned it. You might be able to bypass it just to see if that is the issue.

[IanFrancisco]

Can't bypass the clutch switch because of inspection regs. I'm going to try pulling the switch apart and cleaning it. The key switch part is what's bothering me. It makes sence that bad contacts could cause these problems, but it sounds too simple.

These bikes aren't shuttle technology, but they are 20+ yrs. old. I cleaned my clutch switch, wasn't hard just be careful pulling it apart. If I remember correctly there are little springs under the contacts that can get lost. The hi-lo switch is even more complex, has springs and balls under the contacts.

[bgmart450]

If I remember correctly there are little springs under the contacts that can get lost.

Been there... done that....

On that side you could easily loosen the control box and flip it upside down to keep those little bits from falling out and find the nearest same colored crack top fall in.

[Anonymous]

If I remember correctly there are little springs under the contacts that can get lost.

Been there... done that....

On that side you could easily loosen the control box and flip it upside down to keep those little bits from falling out and find the nearest same colored crack top fall in.

That is a good tip! I have come close to loosing the spring in both the clutch switch and brake switch. Spent about a half hour looking at the ground under my bike the first time I took one apart.

I'd leave the exhaust alone unless you have to take it off, but here is what I did to get a broken exhaust bolt out...If you can remove the exhaust you can try either vice grips on the small bit of bolt sticking out or using a dremel or similar tool to make a slot for a screw driver. I'd get some good penetrating spray, like WD-40 but better. Can't remember the exact name but the guys at any autoparts store should be able to recommend something if you don't already know what I am talking about. The vice grip trick worked for me after I snapped the head of one of the bolts.

[UncleMike]

PB Blaster. Best there is.

[snark]

The turn signals now work. Any advise on the horn? The handlebar switch box was replaced with one from Ebay and it seems to be working fine. I've tried a spare horn that I know works with no luck. Is there a seperate ground for the horn I may be missing?