gs450 project from Aus

[AlphaDogChoppers]

I have a question and hoping to get some help. The ignition coil I have is broken so I just have the switch, however it has 4 wires going to it. Is there a way I can just rewire in a 'on/off' switch? I'll try an get a photo soon to help.

I am assuming this is a typo, and you meant to say "ignition switch" not "ignition coil."

Yes, you can just use a switch. The GS450 ignition switch has "Off," "On," and "Parking Light" positions. The parking light position lights the tail light, but all other circuits are off. You don't need or want that circuit.

You will need a double pole switch. "On" connects the orange and red wires, (ignition circuit,) and the gray and brown wires, (lighting.)

[Collo]

Oh man, that's just the help I was after, and yes I did mean ignition not coil.
Thanks heaps, I will sort that out soon, the ease of stealing it shouldn't be an issue so not too worried.

[peteGS]

Just one thing to watch with that Collo is up here it won't pass a roadworthy like that, not sure about you guys down there though...

[Collo]

Cheers pete, funny each state has it's on compliance requirements.

[peteGS]

Yeah we can't get away with much up here...

[Collo]

Hi,

Got the bike started today. Painted the tank with cans and no booth but it's 'good from far, but far from good'.

[Collo]

Getting a fair bit done this week. All up and running, rear brake working and seat is coming along. Having problems bleeding the front brake it wont pump any pressure.

Also the clutch seems stuck as the clutch rod is loose and spins freely is that broken? I can run the bike on a stand and change gear without the clutch but pulling the lever doesn't change a thing.

It's going to a shop next week to have some things looked at so it will be ready for the road. Roadworthy all taken care of...can't wait to ride it!

[Big Rich]

Sounds like maybe the clutch cable just needs adjusted? I'm pretty sure the clutch rod should spin freely (most don't though because of all the dirt / oil that works its way around).

[peteGS]

Hey Collo, good stuff!


With the brake, try getting a big syringe on some hose that will snugly fit the bleed nipple. Crack it open and push some brake fluid up from the caliper end. Be careful you don't overflow the reservoir. Tighten the nipple and try bleeding again.


If it still doesn't bleed and firm up nice and tight, give the brake lever some real good firm squeezes to the 'bar with the bleed nipple tightened up and then strap the lever tight to the 'bar with some rope or a bungy cord or whatever and leave it overnight.


Pretty sure yours is an '82 like mine, and you'll find your clutch pushrod that is spinning is only a few inches long as it's a two part rod. That will explain the spinning.


As Rich said, sounds like you need a cable adjustment.


The other thing is that after sitting still so long, the clutch plates won't be working normally. Once you try to get her motivated under her own steam with the properly adjusted clutch cable the plates should free up nicely in theory.

[biggiesmalls]

Just catchin' up on your ride here, Collo. Lookin' good man. Definitely signing up.

[Collo]

Thanks for the tips guys, I've been busy with it all day and still no front brake or clutch. Also I ran the bike on reserve but it cuts out. Runs okay but not perfect on 'run', Might be that the carbs are a bit clogged as it jumps and splatters a little. I did take out the fuel filter but would that make any difference?

When I pump the front brake without the MC lid, every pump blows bubbles in the reservoir, is that normal?
Pete, my bike is an 81 model so it might have the once piece clutch rod.  I swear i've pumped the lever a million times already!

Seat is frustrating me and getting to the point where I'm over it all... lol

[Collo]

Think I worked out the brake issue...
The piston seal in the calliper is not working properly as it makes bubble noises and leaks somewhat. Should be an easy fix

[peteGS]

Not sure if the 1 piece pushrods spin or not as I've never seen one myself, but I'd focus on getting the cable adjusted properly and see how it goes from there. When I first started mine the clutch didn't really disengage properly for a fewe minutes.


As for the brake, if you still have the original MC on there, I'd get a piston and cup set from Suzuki and replace them so you know it's all good.

[Collo]

So ordered the new brake piston seal and still no better. Front brake grabs but releases itself almost immediately even with the lever depressed. It's losing pressure from somewhere. Anyway, I'm getting the seat upholstered this week. Ended up laying a fibreglass mould over the seat pan, buying and shaping some foam and handing it to the pros to cover.

Still no luck with the clutch but I'll sort that out later; it's really the brake that's annoying me. Could it be the lever MC seal?

[dukeninja]

Hey man, I replaced my levers with shorty ones and an updated master cylinder. Bleeding was a right pain. I tried quick pumps and long ones that I held in for a few seconds. The latter worked better. I also found that having the bike upright/on centrestand made it easier for air to escape to the m/c.