1982 GS450 Build

So I've been able to get the bike on the road a few times yet and its a blast!

I've not been able to get my exhaust welded together yet so it's running open pipes now and I kinda like it. Sooooooper loud, and I would definitely get sick of it, but for now I'm ok with it.

It seems I've got the jetting pretty dang close to where it should be. No stumbles along the way, plugs show a bit lean but I'm guessing that once I get the mufflers on they should help richen it up a tad.

I'm hesitant to start doing any real tuning to the carbs until I've got the mufflers on as I know that they'll change everything that I accomplish. So for now it has a few issues.

No pics for now. But soon!
 
So I still don't have the exhaust on. Should finally be getting that sorted out tomorrow morning.

Did a little adjusting to the carbs since I'll be riding it about 35 miles round trip to get the exhaust welded up. I had a wicked lean Pilot circuit with the K&N's and open headers, popping on decel, gnarly hanging idle - right around 35-4500rpm with the clutch in, made me feel like a fool coming to stops. Simply upped the pilot jet one size and it seems to have cured my woes. Now it seems to have a -slight- bog off of idle, some adjustments to the mixture screws and I should be golden.

Once I get the mufflers back on I can start sorting out the carb tuning for realsies.
 
Finally! I've got my mufflers on!

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Simply brazed on a couple of 1-3/4" OD tubes to my odd Suzuki sized headers and was able to slip the mufflers right on over that!

Still sounds pretty mean, but at a much more civil volume.

Next I've got some finishing parts for the exhaust to sort out. The chrome heat shields under the pegs will go back on, clean up the look and keep from melting my boots. I've also got to make a couple hangers for the mufflers to rest on, probably not necessary but a piece of mind, the right side will double as a place to attach the return spring for the rear brake.

Then the seat. I've got a pretty good idea of where I'll be taking that, just need to find a little free time to take care of it!
 
Yep, that's the Colorado weather for us. Killed a lot of my plans too. Over 8" right now I believe.

Excellent work Jeff! Any advice on cleaning up the wiring? I'm looking to do the same thing with my bike - put it all in one, albeit messy, place and clean it up a whole lot. I've heard some things about the GS electrical system. Any words of advice (or, you know, a detailed how-to) would be appreciated!
 
Yeah, and my 'Spring' Break just started today...All I was looking forward to was a week of no obligations and motorcycle cruising.

Thanks! Just take it easy, one set of wires at a time. It's a pretty simple system as it is, a few redundant routes but easy enough to understand. You've probably heard of the charging system. The Stators and R/R's are notoriously prone to quitting.

I'm not sure if you're already over there but the GS Resources is a wealth of knowledge on the GS series, Specifically a member named Bikecliff has put together this site: http://members.dslextreme.com/users/bikecliff/ Which contains most of the info and how-to's.
 
Thanks man. Someone else here just recommended GS Resources as well. I've skimmed it and it already seems like a great resource.
 
In between the snow and rain I've been able to do about 700 miles and it seems to be doing great! I've had to fab up some brackets to hold the mufflers from bouncing around and allow for a return spring on the rear brake.

For some reason the horn has stopped working, a scary thing to find out when there's a car trying to turn into you! I'm sure it's something stupid simple, just need to find some time to take a look at it.

I've got the jetting fairly spot on. I'm still at 140 mains, which may be a little richer than needed but I'll take the cooling to be safe. The pilots are still only one over stock and the mixture screws are only out 2-1/2 to 3 turns on either side. I've still not experimented with shimming the needle at all, but the mid range only seems slightly lean, so I may tinker some this summer.

Overall its running solid with only a few minor issues along the way!

IMAG0585_zpse7a8ab77.jpg
 
I think you'll find that if you drop down to a 135 jet, and raise the needle with one shim, you should be right about where you need to be.
 
Thanks AlphaDog. I took your advice on another thread and started with the 140, which was much higher than I expected to be at but seems to be a good starting point.

Just a quick question about 'shimming fundamentals', I was planning on using the small washers that I've heard can be purchased from RadioShack. Is that what you'd recommend? Or are there other washers that might be better suited?
 
Any washer that fits will do. I buy #4 washers at the hardware store, stack them on a machine screw with a nut, chuck it in a drill, and grind down the OD till they fit.
 
I only have the one with the battery in it and this one:

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I thought it was funny, "I am Electronics Tray - Insert Wires."

It's essentially thin gauge aluminum sheet from Ace hardware. I made a paper template of the shape, traced and cut the aluminum using tin-snips. The bends aren't precise by any means but it does a good job. I created overlap in certain areas and then riveted the two+ pieces together.

I've got nearly 3000 miles on it this year and everything seems to be holding up just fine!
 
What tires are you using? I've been looking for newer style rubber for my '82 gs450 TX for a while with no luck... Sorry to resurrect a pretty much dead thread. ;D
 
Pretty sure they're the bridgestone battleaxe bt-45. I like them, I can only compare them to the crummy stock ones. I've heard pirelli and Avon both make some that will work with our weird rim sizes. Check out thegsresources.com if you haven't already.
 
Sorry to revive an old thread.
Getting started on my first bike/build whatever.
It is an 1981 GS450L.

I like the look of your back fender.
Any chance I can get some close up pics of it and under the seat look too.
Thanks
 
I've recently replaced the seat and somewhat redone the fender so it isn't quite the same anymore, the set-up in earlier in the thread is simply the stock fender cut back considerably and mounted in the stock location. I run the 'Lucas Style' taillight and have a couple smaller turn signals off the side of that.

My current set-up is similar so I'll snap a couple pictures for you later tonight if I can, what better time to update the thread anyway!
 
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