GS450T misc tech questions

[normcoffey]

Hello all,

I just bought a 1981 GS450TX with only 4,700 miles and I have a few questions please.

Does the air box come out somehow? Looking into it I see a fine metal screen, does it pull out and is the filter behind it?

Also, the front brake drags really bad, I guess I am looking at a rebuilding as I guess it doesn't release enough when the lever is released? Any other suggestions?

Lastly, with the front wheel off the ground, the steering is very stiff and bumpy to turn. I figure the bearings are gummed up and dirty. I plan to dissassemble, clean, re-grease and put it back together. How tight should I make the stem nut?

Thanks for any help.
Norman
PS: I also own a 1983 GS850GL.

[Dink]

Only way to get the airbox out is to remove the carbs first.
If you look in the reservior of the brake maste cylinder, there are two holes in the bottom, the one closest to the banjo bolt is the return hole, poke a needle (or similar)into it to clear the port. Flush the brake fluid, and then decide if it needs rebuilding.
Replace the steering head bearings if they are feeling notchy they are stuffed.

Dink

[duaneage]

First thing to do is buy a manual from a shop, best 25 dollars your going to spend. Then read carefully the sections on brake repair and front end service. If you don't feel your up to the job, either through lack of tools or experience, I would recommend having a professional repair the brakes and headset. If you already own an 850 do you do your own repairs or does someone service it for you?

he front caliper is likely bad due to sitting for a few years and adjusting the headset bearings can be a bit tricky. You may need new bearings too, which requires a few unique tools to change. I use a special wrench for adjusting the stem bearings, it came from a bike shop and is used to perform the same operation on a bike. THe bearings should have no play yet be able to move freely. This means no dirt and rust are alowed inside.

I'm curious as to why you need to remove the airbox. If you need to repair the carbs they come out without removing the airbox.

Congrats on finding a low mileage 450 like that, I would love to have a 450 that wasn't an L model. They are a little hard to find around here.

[normcoffey]

Thanks for the input guys. I do all my own wrenching. I bought the 850 in non-running condition and she is now running and looking pretty good. As for the 450, I will pick up a caliper rebuild kit and clean / re-grease the steering bearings. I wanted to remove the airbox as being unfamilier with it, it is either missing the air filter or I am confused about it. I see a fine mesh screen at the front side that does not seem to be removeale when I look into the box. By the way, the battery was a real bugger to remove being wedged in under the airbox.

[Nessism]

Keep the airbox and replace the air filter. The filter is just a flat piece of foam that is sandwiched between two screens so to speak. You flex the screen to get it out the top of the airbox. Uni makes flat filter material that is quite a bit cheaper than ordering a factory filter from Suzuki. Just trace out the pattern and cut out a new filter.

Rebuilding the caliper is very easy. Use compressed air in the inlet fitting to push the piston out. You should take the old one apart before ordering replacement parts. If the piston is pitted (likely) you are going to have to get a new one. If not, just seals will do. Again, very easy.

Good luck.

[nabrams]

On my CB750, the pistons just needed to be freed up, resevoir holes opened and fluid replaced. But the whole bike was almost rust free, so if you're bike has got rust then it's likely to need a rebuild.