1980 gs450 project, oh boy

[MLow]

Ok. Saw your pics, and your particular 34s do look different from the GS1000 34s. That said, may be worth a shot to see if at least some parts interchange... maybe the bowls, idle screw, floats?
Seeing that we're neighbors, you're welcome to any and all parts that may work for you. I'm buried in ACL fest for the next few days; come up for air next mid-week, so perhaps we can meet up then.

Sounds good man.

[MLow]

Ok so I might have run into a road block. I was looking over the service manual and got to the clutch section. Interesting design, different than what I expected at least. So I went to look at the push rod in there and it pushes in and out about an inch. I'm wondering if that is normal. I don't have any bolts to put the sprocket cover on and test the clutch lever with though. So I don't know if there is damage or what I'm dealing with it kinda has me freaking out.

[jeffasaurus2]

My clutch push rod does that also. As far as I know its normal, at least, I ride with it like that no problem.

Think it has something to do with the fact that our bikes utilize a two part push rod?

[850 Combat]

Those are cool. I actually thought about buying one in the day. The "S". I still might, if the right one crossed my path.

[MLow]

My clutch push rod does that also. As far as I know its normal, at least, I ride with it like that no problem.

Think it has something to do with the fact that our bikes utilize a two part push rod?

Whew, good then. I tried to push it in but maybe I couldn't get proper leverage cause it didn't budge with my hand.

I'm missing a lot of bolts, is there somewhere I can look for what sizes to buy? I assume it's mostly metric? I have a bolt company that gives me good deals and is helpful but they know squat about bikes.

[jeffasaurus2]

If you're looking at the Suzuki parts fiche it gives the bolt size and length in the part number. I don't exactly remember how though, hopefully someone wiser will chime in.

[MLow]

If you're looking at the Suzuki parts fiche it gives the bolt size and length in the part number. I don't exactly remember how though, hopefully someone wiser will chime in.

I'm looking at a clymer up and down. Can't see any mention of the sizes just torque settings for all the bolts.

Ugh.

[jeffasaurus2]

Go to G&S Suzuki's website and look up your bike. They give Suzuki direct part numbers for bolts, the last 5 or so digits give diam. and length somehow

[Larry D]

You guys know how to use the search feature....right ?

http://www.thegsresources.com/_forum/showthread.php?t=137913&highlight=bolt+sizes

[MLow]

Ohhh my god thank you guys so much. Totally on track now for bolts. I just need to comb over the bike and check everything that is missing or looks old. Or hell, replace them all! ahahah

So allen head stainless steel for things like the sprocket cover. What about parts like the pegs where there will be more stress? Grade 5 or 8 with a coating? Maybe put some lithium grease on the head to help it a little with rust?

I'll hopefully get a list tonight and pick them up tomorrow. Either from home depot or a bolt company monday when they open.

[MLow]

So while I was combing the bike for bolt sizes and such I got some presents in the mail. Oil filter and seal(figure it probably needs a change), used gs450ga 1983 throttle and RH side switches, 1980 gs450et left hand switches and grip, and exhaust gaskets. So I put those grips and switches on, really fleshes out the whole handlebars :P. Still need the clamps for the top(in the mail) and I can snap a pic yay.

As far as the clutch push rod goes, no idea if the clutch is frozen or what cause I can't budge the thing. Would probably help if I have the sprocket cover bolted on though.

The tank bolt has me confused I'm trying to find the size. Also missing a rubber bumper for the right side. Gunna be hard to find that size. Almost impossible to find that rubber bumper thing. Any ideas?

[pete]

Hey mate, welcome! Definitely a long way to go there!

Your carb diagram you posted is not the right one for your carbs, that looks like the earlier 400/425 carbs perhaps, but definitely not the 450 carbs.

The idle adjustment is underneath to start with...

The carbs are BS34SS and the float bowls have the pilot and main jets in them.

[MLow]

Hey mate, welcome! Definitely a long way to go there!

Your carb diagram you posted is not the right one for your carbs, that looks like the earlier 400/425 carbs perhaps, but definitely not the 450 carbs.

The idle adjustment is underneath to start with...

The carbs are BS34SS and the float bowls have the pilot and main jets in them.

Best I can tell I ordered the right carbs off ebay: http://www.ebay.com/itm/331030614287

Tell me what you think.

I really appreciate your feedback, I read like 50 pages of your rebuild thread the other night. Some pretty cool pics of the internals, and your paint job.
Quite the journey.

We're getting close to the point where I want to test fire it. It last ran a couple years ago, according the guy I purchased it from. So we will change the oil, check the electronics and wire things up. When the exhaust/carbs come in there wont be much to do other than try to fire it up.

Have yet to go over the electronics more than, what's missing, whats not, but as clean as the electronics look(ignitor unit, R/R, coils, plug caps) I'm thinking they work.

So maybe some backstory is needed. Apparently the original owner let it fall to disrepaired state(probably let it sit and carbs got stuck) sold it cheap. New owner junks the old rusted and torn parts, puts custom janky replacements on, rides it til he gets bored(it is a 450 from 1980) then sells it to a guy who repairs bikes, this guy then has a garage full of bikes and realizes he has too much on his plate and sells them off to a guy I know who promptly buys too many 'projects' of his own. That is where we are. So the bike has been apart for about 2 years, before that it was ridden as some kind of franken bike. I've bought a lot of used original parts, they are starting to slowly 1 by 1 come in the mail, and bolted on.

What can I do to go about testing the condition of the engine. I put it in first and pulled the plugs to push it around and see if it had compression(it does, very hard to push in 1st even with plugs out). Lot's of plop plop sounds. Air sounds, not mechanical. So I assumed that things can't be too bad in there.

Should I change the oil, try to run the starter with plugs in? Mind you it has no carbs or exhaust. So it will just be a test of compression and the starter basically. But would that hurt anything to do a short test? Just to make sure the starter works, and that loud bangs don't happen or something like that. I'd really rather not strip the whole motor down, when I have no reason to believe it's broken. Like I said 2 years ago, running, was since taken apart at some point.

[pete]

Thanks mate, doing my 450 was fun and I still love ridin' it every day.

Those carbs are the right ones, good score there.

To compression test, all you need is the starter motor and a good battery. Either leave the carbs off or if they're on, you need to hold the throttle wide open.

Let the starter turn it for a few cranks with the gauge in the plug hole and see how it goes. If it reads low, add a few drops of oil and try again.

Keep in mind compression usually looks low on an engine that hasn't been run for a long time.

Also, valves out of adjustment can impact compression figures.

[MLow]

Thanks mate, doing my 450 was fun and I still love ridin' it every day.

Those carbs are the right ones, good score there.

To compression test, all you need is the starter motor and a good battery. Either leave the carbs off or if they're on, you need to hold the throttle wide open.

Let the starter turn it for a few cranks with the gauge in the plug hole and see how it goes. If it reads low, add a few drops of oil and try again.

Keep in mind compression usually looks low on an engine that hasn't been run for a long time.

Also, valves out of adjustment can impact compression figures.

How hard is it to do the valves on this engine, I did it on my ninja and it was a pain! But it did improve wheelie time 10 fold. J/K, but it made her purr way better. Needed carb sync afterwards.