1981 GS450E Rebuild

[landshark]

The only thing making me hesitant about that was the choke lever, but if I'm able to do what I want and make it handlebar mounted, then that problem goes away. I think I have an idea on how to handlebar mount it that may even work too...

The GS1000's like mine have the choke cable come up through the triple clamp/steering stem, maybe you are able to do the same thing?

[pete]

The GS1000's like mine have the choke cable come up through the triple clamp/steering stem, maybe you are able to do the same thing?

I had actually thought about that early on, but I'm pretty sure the 450 stem isn't hollow so I don't think I could just try for a 1000's headstock bolt or anything.

I'm thinking along the lines of the later model GSXR left controls as they have a choke lever on there.

I should be able to fabricate a bracket that goes directly on top of the left carb's diaphragm cover and by removing the choke lever I should be able to connect the choke cable directly (with a fabricated adaptor) onto the choke actuator instead.

[pete]

Got a favourable response from Slipstream Performance this morning, looks like I can get the O ring chain, a matching front sprocket to my rear, and the K&N pods all for a reasonable price plus I get my 10% discount

Will order them next week after pay day...

Now if only the igntion components would hurry up and get here...

[hillsy]

Now if only the igntion components would hurry up and get here...

Hey Pete - might be too late, but I found this little nugget today:

http://www.jaycar.com.au/productView.asp?ID=KC5442

Looks interesting

[hillsy]

Ummm....on second thoughts it says "suitable for single coil engines".....

Bummer

[pete]

Yeah I had to go peek, but no go for us I'm afraid, and not sure on how it would go with our mechanical advance either.

On another note, my dad's talking about giving me his old welder... all I know is it's huge and is on a trolley and it still works... could be another interesting way to injure myself...

[landshark]

On another note, my dad's talking about giving me his old welder... all I know is it's huge and is on a trolley and it still works... could be another interesting way to injure myself...

I've got a stick welder if you are ever in need.

[pete]

Cheers, that's good to know!

At the moment I have no specific need to have a welder, but it could be handy depending on what I need to do with the seat pan and choke actuator.

[landshark]

Cheers, that's good to know!

At the moment I have no specific need to have a welder, but it could be handy depending on what I need to do with the seat pan and choke actuator.

If you are interested in going the way of the steering stem choke check yours to see if it is hollow and i will measure mine up.

[landshark]

I had too much time on the internet today, but at least this should make us all feel good about what our bikes must be worth!
Imagine what a fully rebuilt 450 must be worth?

http://cgi.ebay.com.au/1980-Suzuki-GS1000G_W0QQitemZ150558590467QQcategoryZ102680QQcmdZViewItemQQ_trksidZp3286.m7QQ_trkparmsZalgo%3DLVI%26itu%3DUCI%26otn%3D4%26po%3DLVI%26ps%3D63%26clkid%3D7583619836608648727

[pete]

If you are interested in going the way of the steering stem choke check yours to see if it is hollow and i will measure mine up.

I'll have a think about it and see what GSXR controls are worth too. My controls are a little not so nice and new anyway.

Mind you, I need to take the instrument cluster back off to lube the guages and I need to take the top triple clamp off to swap the headlight ears, so while I'm there I might as well check. Probably won't get to that until I sort the ignition though, providing the modules show up tomorrow.

I had too much time on the internet today, but at least this should make us all feel good about what our bikes must be worth!
Imagine what a fully rebuilt 450 must be worth?
http://cgi.ebay.com.au/1980-Suzuki-G...19836608648727

When I lived in Burpengary there as an '80 450E for sale freshly rebuilt for $2500... I was sorely tempted considering I hadn't even been able to split the cases at that point

[pete]

Express post parcel waiting at the PO Box for me today containing this:



Which contained these:



Jaycar delivery nice and quick, but no HEI modules yet.

I also discovered I have some heatsink compound:



So, even though my old college project doesn't work in terms of providing 12 volts DC, it does still provide me some testing facilities if I use an external power source.

So, cleaned it out and got it ready:



Dug out my old soldering iron, PCB stand, and solder:



Then stripped and tinned the wires from the OEM ignitor connector:



Hooked the ignitor connector leads to the connection posts on my board, and as the first way I'm testing is like the GS1000G setup, I'm leaving the black/white common lead from the pickup coils disconnected:

[pete]

And popped the resistors and diodes in waiting for the HEI modules:



I also noted down the correct colours for the pickup coils compared to the GS1000G colours:



And, finally, I figure I should be able to mount a plate in here above the battery to bolt all the electrics to, and it should allow me to have the HEI modules on top bolted to the heatsink below which, with no airbox, should provide a nice airflow to keep them cool:



Just need to get a sheet of metal, will be very rudimentary but should be effective.

Fingers crossed the HEI modules rock up tomorrow, but I'm not holding my breath given the "speedy" responses from the seller initially...

[davidduarte]

SNIP

Mind you, I need to take the instrument cluster back off to lube the guages...SNIP

what would you use to lube the gauges, and (perhaps more importantly) how?

[pete]

I've done a search on here and anything from some high RPM grease to WD40 has been used to good effect.

Apparently spraying some through the cable connection with the guages inverted should help, but if it doesn't help, it's possible to disassemble and lube the mechanism directly.