GS450 "Sport" - Done!
- Thread starter Big R
- Start date
Hoosier Daddy
Earache my eye...
Re: GS450 "Sport" - airbox work....
Day-Ja-Voo-Doo
Day-Ja-Voo-Doo
Big R
Heaven is so far away.
Re: GS450 "Sport" - airbox work....
Time for a small update I suppose......
The airbox idea got tossed in the trash. All factors considered, it just won't work. The frame just isn't designed for an easily installed airbox - whatever I can fit in the frame didn't come in and out the way that I wanted. I still have a couple ideas, but riding season rolled around and, well, you know......I've been riding! But here's a picture of a cool little bug that wanted to take the 450 for a spin:
Time for a small update I suppose......
The airbox idea got tossed in the trash. All factors considered, it just won't work. The frame just isn't designed for an easily installed airbox - whatever I can fit in the frame didn't come in and out the way that I wanted. I still have a couple ideas, but riding season rolled around and, well, you know......I've been riding! But here's a picture of a cool little bug that wanted to take the 450 for a spin:
Big R
Heaven is so far away.
Re: GS450 "Sport" - airbox work....
One thing that did get upgraded was my auxiliary / fog light bracket. The original "U" shaped bracket was only about .080" thick and cracked around the mounting bolt to the frame. With a little bit of sheet metal, drilling, and hammering, I came up with this (sorry for the dark pics):
You can see the original bracket on the right
The new bracket is about .100" thick
There are some pretty big changes planned for the bike when winter rolls around, but the 650 is coming first and foremost. I just don't want riding season to roll around with a garage full of projects.
One thing that did get upgraded was my auxiliary / fog light bracket. The original "U" shaped bracket was only about .080" thick and cracked around the mounting bolt to the frame. With a little bit of sheet metal, drilling, and hammering, I came up with this (sorry for the dark pics):
You can see the original bracket on the right
The new bracket is about .100" thick
There are some pretty big changes planned for the bike when winter rolls around, but the 650 is coming first and foremost. I just don't want riding season to roll around with a garage full of projects.
Big R
Heaven is so far away.
Re: GS450 "Sport" - possible 520 chain conversion?
So since I have plenty of time at work to look around online, I started looking into a 520 chain conversion for the little GS's. Seems like it is definitely possible, if not easy. All my searching around has been on JT Sprocket's site just fyi.
Here is the link for the 1980 GS450's sprocket set:
http://www.jtsprockets.com/catalogue/model/1632
I haven't looked at the other GS twin models too much (L, T, different years, etc.) but they are all listed on JT's site.
So since I have plenty of time at work to look around online, I started looking into a 520 chain conversion for the little GS's. Seems like it is definitely possible, if not easy. All my searching around has been on JT Sprocket's site just fyi.
Here is the link for the 1980 GS450's sprocket set:
http://www.jtsprockets.com/catalogue/model/1632
I haven't looked at the other GS twin models too much (L, T, different years, etc.) but they are all listed on JT's site.
Big R
Heaven is so far away.
Re: GS450 "Sport" - possible 520 chain conversion?
As far as the front sprockets go, I think the obvious choice is from a GS500 twin. There are basically 2 different types though (they switched styles around 2004 I think?). The first generation used a clip to hold the sprocket on, and the second generation used 2 bolts (and has a step on the backside of the sprocket).
Here are the links to the GS500 E & F front sprockets:
http://www.jtsprockets.com/catalogue/model/1640
http://www.jtsprockets.com/catalogue/model/5619
As far as the front sprockets go, I think the obvious choice is from a GS500 twin. There are basically 2 different types though (they switched styles around 2004 I think?). The first generation used a clip to hold the sprocket on, and the second generation used 2 bolts (and has a step on the backside of the sprocket).
Here are the links to the GS500 E & F front sprockets:
http://www.jtsprockets.com/catalogue/model/1640
http://www.jtsprockets.com/catalogue/model/5619
Big R
Heaven is so far away.
Re: GS450 "Sport" - possible 520 chain conversion?
Now the rear sprocket is a little tricky. The GS450 uses a fairly oddball sprocket in the back so finding a 520 sprocket with the same dimensions took a little longer. JT makes a 520 conversion for T20 Super Six (X6, Hustler, whatever it's called):
http://www.jtsprockets.com/catalogue/model/1566
And another one I found was for the GS300L:
http://www.jtsprockets.com/catalogue/model/5591
That's all the info I have for now, but might update these couple of posts if I find more info.
Now the rear sprocket is a little tricky. The GS450 uses a fairly oddball sprocket in the back so finding a 520 sprocket with the same dimensions took a little longer. JT makes a 520 conversion for T20 Super Six (X6, Hustler, whatever it's called):
http://www.jtsprockets.com/catalogue/model/1566
And another one I found was for the GS300L:
http://www.jtsprockets.com/catalogue/model/5591
That's all the info I have for now, but might update these couple of posts if I find more info.
ben2go
Two Wheel Projectile
Re: GS450 "Sport" - possible 520 chain conversion?
There were 3 GS500 sprockets.A completely flat sprocket held on with the circlip,a shouldered sprocket held on by a circlip,and a shouldered sprocket held on by two bolts.The splines are all the same.I think it's a case change that dictated the use of a shouldered sprocket.
Big Rich said:
There were 3 GS500 sprockets.A completely flat sprocket held on with the circlip,a shouldered sprocket held on by a circlip,and a shouldered sprocket held on by two bolts.The splines are all the same.I think it's a case change that dictated the use of a shouldered sprocket.
Big R
Heaven is so far away.
Re: GS450 "Sport" - possible 520 chain conversion?
Thanks for the info Ben! I didn't bother looking at all the variations on JT's site...... Now that I think about it, you wouldn't happen to have any old front sprockets laying around would you? Just for comparison / fitting - I wouldn't run an old sprocket.
Thanks for the info Ben! I didn't bother looking at all the variations on JT's site...... Now that I think about it, you wouldn't happen to have any old front sprockets laying around would you? Just for comparison / fitting - I wouldn't run an old sprocket.
Hoosier Daddy
Earache my eye...
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.
Oh my stars!
Looks great Rich!
Oh my stars!
Looks great Rich!
Big R
Heaven is so far away.
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.
Thanks fellas! I've done enough research and fitments to say that it will work. Here are the details though:
Front end:
The fork spacing and diameter is identical between the GS500 and GS850 "G" (I specify the G model because the GL is different). In order to keep the stock ignition lock and instrument cluster, I will be using the GS850 triple tree in it's entirety (also, the GS500 steering stem is shorter, and the stem swap would require machining the upper part of the new stem). The GS450 stock forks are about 29.5" long, with a tire diameter of about 24". The GS500 forks are also 29.5" long, and a 110/80-17 Avon Roadrider tire has a listed diameter of 24.2". So the change in ride height is minimal. The dual single piston calipers that I ran all season will be replaced by a dual piston GS500 caliper as well. Basically, it will get a Gs850G triple tree and GS500 forks / wheel / brakes / etc, with no loss in performance at all.
Rear end:
This is where things get a little bit trickier. Changing from the current 100/90-18 tire to a 130/80-17 tire only raises the rear end by .050", so that's not a problem at all. The swingarm width between a GS450 and GS500 is also identical, so the wheel does physically fit. Obviously there will need to be some fabbing / welding to swap from the mechanical drum to a hydraulic disc brake. The biggest issue is sprocket alignment - the GS500 rear sprocket is 12mm off center from the Gs450's. Late model GS500F front sprockets can be spaced out a little bit with extra lockwashers, and a JT rear sprocket is "dished" (undercut on the bolting surface) - so it can be flipped to move the chain centerline in too. For all the math that I did, the sprocket carrier would still need about 8mm cut back. However, I found out that a rear wheel from a 91-93 Bandit 400 is identical to the GS500 with two exceptions: the rim width is 1/2" wider (17"x4.00" instead of 17"x3.5") and the hub is approximately 8mm more narrow.......supposedly on the cush drive side! I have a Bandit wheel on order, and will confirm all of my fittings hopefully next week.
Thanks fellas! I've done enough research and fitments to say that it will work. Here are the details though:
Front end:
The fork spacing and diameter is identical between the GS500 and GS850 "G" (I specify the G model because the GL is different). In order to keep the stock ignition lock and instrument cluster, I will be using the GS850 triple tree in it's entirety (also, the GS500 steering stem is shorter, and the stem swap would require machining the upper part of the new stem). The GS450 stock forks are about 29.5" long, with a tire diameter of about 24". The GS500 forks are also 29.5" long, and a 110/80-17 Avon Roadrider tire has a listed diameter of 24.2". So the change in ride height is minimal. The dual single piston calipers that I ran all season will be replaced by a dual piston GS500 caliper as well. Basically, it will get a Gs850G triple tree and GS500 forks / wheel / brakes / etc, with no loss in performance at all.
Rear end:
This is where things get a little bit trickier. Changing from the current 100/90-18 tire to a 130/80-17 tire only raises the rear end by .050", so that's not a problem at all. The swingarm width between a GS450 and GS500 is also identical, so the wheel does physically fit. Obviously there will need to be some fabbing / welding to swap from the mechanical drum to a hydraulic disc brake. The biggest issue is sprocket alignment - the GS500 rear sprocket is 12mm off center from the Gs450's. Late model GS500F front sprockets can be spaced out a little bit with extra lockwashers, and a JT rear sprocket is "dished" (undercut on the bolting surface) - so it can be flipped to move the chain centerline in too. For all the math that I did, the sprocket carrier would still need about 8mm cut back. However, I found out that a rear wheel from a 91-93 Bandit 400 is identical to the GS500 with two exceptions: the rim width is 1/2" wider (17"x4.00" instead of 17"x3.5") and the hub is approximately 8mm more narrow.......supposedly on the cush drive side! I have a Bandit wheel on order, and will confirm all of my fittings hopefully next week.
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.
you might want to check these guys out
i have been buying stators and starters (in particular goldwing ones) for years
they dont have everything but what they do have is top quality awesome freindly service
and the price includes shipping and they are fast
http://www.dbelectrical.com/c-9111-suzuki.aspx
you might want to check these guys out
i have been buying stators and starters (in particular goldwing ones) for years
they dont have everything but what they do have is top quality awesome freindly service
and the price includes shipping and they are fast
http://www.dbelectrical.com/c-9111-suzuki.aspx
