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1981 GS450E Rebuild

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    Apparently I have some stainless bolts on the way for the carbs.

    The place at Enoggera doesn't want retail business as they only open Monday to Friday and won't take phone orders.

    Rang a place at Brendale and they took my order over the phone and will courier them out to my work.

    They didn't have the M4 12mm in stock but they hope to have them in tomorrow, so I might get them tomorrow otherwise probably Monday or Tuesday I would imagine.

    Cost should be about $14 plus the courier.
    1982 GS450E - The Wee Beastie
    1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

    sigpic

    450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

    Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

    Comment


      great thread with good info... cant wait to see the finished bike... especially after reading 58 pages...lol
      cant wait to tear into mine... keep us posted

      jeston

      Comment


        Cheers Jeston, I can't wait to see the finished product either!

        It's turned into a little bit of a monster thread, but nothing like some others on here such as Flaming Chainsaws' 450L thread...
        1982 GS450E - The Wee Beastie
        1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

        sigpic

        450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

        Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

        Comment


          Rightio, float chamber time. I'm confused again.

          So, after thinking I had the measuring location for the float height right, I proceeded to make myself a measuring tool tonight.

          22mm long piece of stiff cardboard:



          Measuring:



          Bugger. Now if my measuring position is right, and the range is 21.4mm to 23.4mm, that means I'm about 2mm too high. Wasn't happy with the guess work though...

          So, new measuring tool:



          Measure again:



          So definitely looks about 24mm which is not to far away from being within range. I haven't adjusted the float height yet, will do that next time when I'll hopefully have the shiny new allen bolts to put the float chambers on with.

          Next up, back to the electrics. And bugger again.

          I measure 12.6 volts from the car battery across the terminals, and the same from the bike ground to where I hooked the positive jumper lead to the battery lead on the bike.

          However, I can't do anything to get spark, and I'm positive the left spark plug cap is ok and should give me spark.

          Took the signal generator cover back off to see if flicking a screw driver past the signal generator coils would generate a spark but no go.



          For sh!ts and giggles I put the left controls on tonight to see if I could eliminate a few more disconnected wires:



          And lo and behold I discovered that when I turn my lights on, my speedo actually lights up:



          But I need to do the tacho bulb as it stays out:



          So, I started measuring around the place at various spots where I should be seeing 12 volts, but I see about 10.6 instead. Bugger. That's a lot of voltage drop across the loom and I'm guessing it's probably enough of a drop to prevent spark too, so I need to sort that before even thinking about whether things like the igniter are working ok.

          Time to keep searching around here to work out the best way to eliminate voltage drop, although I know the coil relay mod is one way to help the coils, but it's the rest of the loom that concerns me at the moment.

          Maybe I should just bite the bullet and do the custom simplified harness? Hmmm... more delays on that first start... bugger.
          1982 GS450E - The Wee Beastie
          1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

          sigpic

          450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

          Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

          Comment


            Originally posted by pete View Post
            Cheers Jeston, I can't wait to see the finished product either!
            Yeah! Hurry up, will ya?
            Jeez!

            Actually, I should shut up. That joke I made a couple of months ago about yours being on the road before mine might be coming true..

            I'm going to pull my tank back off this weekend. It's a start... again.

            Comment


              Originally posted by Leigh View Post
              Yeah! Hurry up, will ya?
              Jeez!

              Actually, I should shut up. That joke I made a couple of months ago about yours being on the road before mine might be coming true..

              I'm going to pull my tank back off this weekend. It's a start... again.
              Yeah yeah yeah

              I still think you'll definitely be there first... not gonna get far with only 10 odd volts! In the past I've found it very hard to start a combustion engine with no spark... I don't think that's changed in recent times...

              When I get that sorted it might be full steam ahead though...

              Starting again 'ey? Man I still don't recall seeing those "finished" pic's you were going to take... but I'm keen to see what you do this time
              1982 GS450E - The Wee Beastie
              1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

              sigpic

              450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

              Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

              Comment


                Only a very short time tonight as I need to get up early in the morning to make it to the Suzuki dealer in time so we can do a bunch of other stuff afterwards.

                My shiny new stainless allen bolts showed up at work today:



                Replaced the two diaphragm cover screws I already have in with them (anti seize in use of course) and now I really have to do something at some point about the covers, they look horrible next to those new bolts:



                Unfortunately they sent me 20mm M5's instead of the 16mm M5's I ordered, but the trouble to sort that out is not worth it and I can live with a few extra mm's poking out as they won't interfere with anything. I realise I could hacksaw them to length, but I've got so many other more important things to worry about...

                Like my float height!

                I am completely confused.

                Bent the tang on the left carb tonight to try to get closer to 22mm, got it to 24mm, and the floats are getting quite close to the carb body. If I compress the needle spring, they contact the carb body. That just doesn't seem right... I'll pop a thread in the carby forum shortly as I can't seem to find a suitable procedure anywhere that highlights exactly where to measure.



                So, I then started a bit of electrical troubleshooting. As per a suggestion on another thread by Steve, I actually noted down voltages. I was initially just going to measure away happily until I found the problem, but if I did that I think I would've missed something...



                Not sure how well you'll be able to see, and the schematic is slightly incorrect in that the fuse on the 450 is before the ignition switch (and there's only one).

                So, battery giving 12.63 volts with ignition off, and 12.00 with ignition on.

                Leaving the ignition on, the other side of the main fuse gives 11.40.

                11.40 still on the input to the ignition switch, so connections etc. on the way through seem to be ok, but only 11.14 on the way out, so the ignition is dropping a little voltage.

                I also checked the kill switch which is not in that schematic, and the output of that has 11.13 with it in run, but 12.18 with it in stop.

                When I go back to the battery, fuse, and ignition, they all jump up to the 12.18 or higher with the kill switch off.

                So, first two things for me to visit are the kill switch and ignition switch and give both a thorough going over with contact cleaner and maybe even some sand paper or something if they're a bit corroded.

                Now, the other night I was only seeing 10.6 or so volts at the coils, so after I get these sorted out there's probably going to be something else that's dropping voltage, but I'll get these sorted first then start from the beginning.

                I really feel like I accomplished something there
                1982 GS450E - The Wee Beastie
                1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                sigpic

                450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                Comment


                  Originally posted by pete View Post
                  but I'm keen to see what you do this time
                  Just going to finish off, polish up, redo a few bits I'm not so happy with.

                  Electrics eh? The Black Art.
                  Good luck with finding your lost volts..
                  Have you checked under the bench in the shed? They may have rolled under there.

                  Comment


                    Originally posted by Leigh View Post
                    Just going to finish off, polish up, redo a few bits I'm not so happy with.

                    Electrics eh? The Black Art.
                    Good luck with finding your lost volts..
                    Have you checked under the bench in the shed? They may have rolled under there.
                    Oh so no cafe decision yet then? I'm sure that won't be far away

                    Believe it or not I'm quite comfortable with electrics, but I'm short on patience when it comes to sitting there measuring for voltage 20 times...

                    In the shed 'ey? Well I haven't looked there!
                    1982 GS450E - The Wee Beastie
                    1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                    sigpic

                    450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                    Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                    Comment


                      Well, got all my parts except the spark plug caps today, and I guessed the wrong part number for the pilot air screw spring

                      I used one from about a 77 or 79 and the diameter of the spring is too big.

                      Unfortunately, none of the online parts fiches I can find show this spring, and I had to go back to find one but it don't fit. I'm assuming this is because of the emmissions laws that came into effect to prevent that screw being adjusted.

                      I just went through all the rags again but still no sign of the spring, but the house mate moved them again on Thursday, so if it happened to be there then, it ain't now... I really need to look in the daytime with some decent light.

                      Anyways, I can at least now get the carbs fully assembled (that pilot air screw can go in later) and get the valve cover on at last.

                      Once I sort that spring and the electrics/spark issue, I can give it that first start finally...
                      1982 GS450E - The Wee Beastie
                      1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                      sigpic

                      450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                      Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                      Comment


                        I've been following this Pete and trust me, I'm excited for you and hope it starts up and runs without any problems.
                        Cowboy Up or Quit. - Run Free Lou and Rest in Peace

                        1981 GS550T - My First
                        1981 GS550L - My Eldest Daughter's - Now Sold
                        2007 GSF1250SA Bandit - My touring bike

                        Sit tall in the saddle Hold your head up high
                        Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
                        and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

                        Comment


                          Cheers Cowboy, I appreciate the comment. I feel like I can almost touch that moment...

                          Don't happen to have a part number of a '81 450E pilot air screw spring handy?
                          1982 GS450E - The Wee Beastie
                          1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                          sigpic

                          450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                          Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                          Comment


                            Have you looked at this one?

                            37.JET, AIR (1.6)
                            09493-32003 2$10.21

                            It's from the Motorcycles 1980GS450 ET,ST,EX,SX,EZ 1980-1982

                            Carburetor Microfiche that I found on this site - www.apexsportsinc.com (my local bike shop). I don't know if it fits for your bike or not but maybe? I'm still learning what every part is so maybe I'm wrong but if you go there you might find what you are looking for.
                            Cowboy Up or Quit. - Run Free Lou and Rest in Peace

                            1981 GS550T - My First
                            1981 GS550L - My Eldest Daughter's - Now Sold
                            2007 GSF1250SA Bandit - My touring bike

                            Sit tall in the saddle Hold your head up high
                            Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
                            and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

                            Comment


                              Originally posted by cowboyup3371 View Post
                              Have you looked at this one?

                              37.JET, AIR (1.6)
                              09493-32003 2$10.21

                              It's from the Motorcycles 1980GS450 ET,ST,EX,SX,EZ 1980-1982

                              Carburetor Microfiche that I found on this site - www.apexsportsinc.com (my local bike shop). I don't know if it fits for your bike or not but maybe? I'm still learning what every part is so maybe I'm wrong but if you go there you might find what you are looking for.
                              Unfortunately no Cowboy, but thanks for trying

                              If you look closely at the fiche, you'll see parts 14, 15, and 16 which go on the throttle shaft end.

                              Straight on top of that, below the choke shaft, you'll see another round bit, and that there is where the pilot air screw (or mixture screw if you prefer) is concealed on US models, which also contains the spring that I dropped.

                              As you can see, it don't exist on the fiche...

                              I did go spring hunting today with no success, both in the garage and in some auto shops...
                              1982 GS450E - The Wee Beastie
                              1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                              sigpic

                              450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                              Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                              Comment


                                Well... part frustrating and dissapointing today, part success...

                                First off, all the bits I got yesterday and a couple I got today:



                                The spring there was my guess from an earlier model's carbs but is wrong, too large a diameter. So still without a pilot air screw spring for the left carb at present.

                                The spark plug caps are all I could get today and the guy in the auto shop reckons that's all he gets asked for from motorcycle customers. According to the NGK numbers, it should be ok I guess, it just has no built in resistor. I don't think that's a problem though as I'm pretty sure the OEM caps don't have one either.

                                I checked three different auto stores today for the spark plug caps and also to see if they had some miscellaneous springs around I could use for the lost spring, but no dice except the caps.

                                So, tonight, I started off by removing the ignition switch and right controls as they both need some attention going by my electrical troubleshooting the other night:



                                Then, time to fill these empty spots:



                                A little sealant on the curved surfaces of the new half moons and in they went:

                                1982 GS450E - The Wee Beastie
                                1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                                sigpic

                                450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                                Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                                Comment

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