gs450 re-build

[pete]

The set I have on the bike now are from the '82 model... no clue what the other set of carbs are... They came on the chopper when I got it and it's definitely a mixed match bike.

Hmmm I guess see if they have some markings on the body somewhere? I think they're supposed to have the model on them, but I don't know a whole lot about the different carbs, just that the '80 - '82 used the BS34SS and the '83 onward changed to something a bit different.

The good thing with the later carbs is that Dynojet sell a stage 3 jet kit for them, whereas they only have a stage 1 kit for the BS34SS.

I read how to test the alternator in the Clymer manual? Is it really any more complicated than that test to figure out if it's bad or not?

I figured I'd test the alternator when I get home, and if it's good then I'll switch out the reg/rec. If the alternator is bad, well that's one more thing I'll rob from my wife's project bike that she has pretty much decided she doesn't want haha.

The stator papers etc. will get you testing the stator as well as the R/R, so everything in the charging circuit is covered off as to whether it's good or bad.

There's a very easy to follow flow chart there.

[mlc216]

I'll check out the carbs and see what I can find on them.

I did the no load test and didn't get 75 volts from the alternator. Actually didn't get much of anything... So I guess my stator is toast. Hope the one on the other bike is ok!

[mlc216]

Ok so I thought it was weird that I didn't get much and apparently I had the voltmeter set on DC instead of AC.... 3 phase, duh! So I went back out and tested again and two combinations gave me about 66v and one combo gave me like 34v. So, the stator is still bad. I also ordered a new rectifier today from a source who has them for 42.50 shipped! So I'm going to switch the stator over from the other bike and put the new r/r on and hopefully all will be well then.

[mlc216]

I think sooner or later the 30 year old wiring craps out and kills the stator and/or regulator/rectifier.

So I've decided to make a few changes... This motor:


Is going in the chopper:


But not before some cleaning and polishing:


Here's a good comparison:


Stripped it down to nothing, redid the battery tray, smoothed out a few things, and made a mount for new switches.


And then it got a few coats of paint


Much more to come tomorrow

[pete]

Man you work fast!!!

You'll definitely notice the difference with the polishing.

Why the motor swap? Anything in particular wrong with the original?

Frame looks good with some paint too.

[mlc216]

I noticed the other motor smoking a little at idle. Plus this motor has had gaskets replaced in it recently and is probably in better shape overall. I'm hoping the stator in it is still good otherwise I'll be ordering one soon. Yeah I think the cases really look good now and it didn't take much work at all!

[pete]

Cool, that all makes sense.

I also paint stripped the Suzuki emblems both sides and I like them much better polished with no black.

[mlc216]

Yeah the paint was coming off as I hit it with the polishing wheel. Probably gonna finish it off and leave it all polished...

Didn't get much done today...

But it's back to a roller...

[mlc216]

It moves along so quick because I'm ready to ride! haha

Anyways made some more progress tonight... put the newer motor in, mounted seat, taillight, tag, and rear brake. Done for the night... Gonna be a busy week if this bike is gonna be ridden this weekend!

[Flaming Chainsaws]

My bike doesn't even have the Suzuki emblem on the engine . And the engine covers are scratched to hell. Looking good!

[mlc216]

I just used a blue scotchbrite rotoloc and red compound on some buffing wheels I got from Harbor Freight. Really didn't take that long... Looks good, but could be mirror like with more work...

[mlc216]

Got my stator put in tonight. Took a little bit longer than I thought, but hopefully I'll finish up the wiring tomorrow night and maybe even get to ride it!

[mlc216]

Well we closed on the house today... Can't wait to get moved in and start using my garage!

[Flaming Chainsaws]

Awesome! Looks like a two car garage? I want my own garage...

[mlc216]

Well it was a carport that they closed in... I guess it's two cars big?... anyways I'll have a car and a couple bikes in it