82 GS450t

Awesome. Thanks for all the info. I'll have to revisit this in the morning--feeling pretty zorched right now.

Dismantled the steering assembly tonight, prepped the triple trees for a fresh coat of paint. Only issue...my lower steering bearing wouldn't budge. I'd like to get it out of there so I can clean and regrease the bastard (looks pretty dry/grungy) and sand away at some little spots of corrosion on the lower trip tree. Anyone know of any tricks to get the lower bearing off that assembly?
 
I started poking around under the bearing race with a flathead but it seemed like I was just going to bend it. I'll try it again with some WD40 tonight. If that doesn't work I'll just regrease the bearings/stem as is and cover them as best I can when I repaint the lower tree.
 
Unless you can get a flat punch on the inside race of the bearing and drift it off, you will more than likely ruin the bearing by trying to pry it off with a chisel.

As you have suggested, just clean and re-grease the bearing in place. Mask it up and spray away.
 
hillsy said:
As you have suggested, just clean and re-grease the bearing in place. Mask it up and spray away.
Click to expand...

Exactly what I did. Need to give it another coat of paint or two before I can start reassembling. Got my clipons today.
 
Dwani6260 awsome video! And i hope you get your gs450t running perfect. Cant wait to see that thing all cafe'd out. If those are your intentions.
 
81650c said:
Dwani6260 awsome video! And i hope you get your gs450t running perfect. Cant wait to see that thing all cafe'd out. If those are your intentions.
Click to expand...
I did one as a bobber -- did the GS450 ESX as a straight E -- one of the automatics as a museum piece (the automatic didn't make it to my youtube) The rest as runners.... I kept one for a flat tracker but I haven't gotten back to it yet due to I have to make a living too -- plus I feel like doing a 750 for a personal toy -- and a VTX1800 as a flat tracker that will also replace my goldwing as my racebike puller
 
Lots of stuff going on.

Got the forks, front wheel/rotor, bars, headlight bucket all tenderly attached. I just ordered a used throttle tube (this one is cracked), but now we can finally start to see what the finished product will look like.

I'd like to push the forks up maybe an inch or two through the triple trees. I also flipped/lowered the instrument cluster but am expecting to replace all that at some point down the line.

2012-03-07_21-53-53_65.jpg


2012-03-07_21-54-16_722.jpg


Still need pod filters, new brake pads, a new battery mount, seat, and plenty of cleaning!
 
If that's how you plan on fitting the seat then you will probably need longer shocks so the tyre clears the seat.
 
Poopwink said:
I'd like to push the forks up maybe an inch or two through the triple trees. I also flipped/lowered the instrument cluster but am expecting to replace all that at some point down the line.
Click to expand...

I was able to go an inch on my GS before contacting the bars due to the triple tree design...


Poopwink said:
Still need pod filters,
Click to expand...

...and a jet kit if you go with pods. Check out Dynojet http://www.dynojet.com/jetkits/ I bet their "SUZ 83 GS450 STANDARD FLOAT" is close, certainly worth a call!
 
Currently trying to determine what I need for my air filters. I've got 34mm Mikuni carbs.

I know to stay away from EMGO's pod filters, are there any other brands I should steer clear of? I figured it would be a piece of cake to get some matching pods but it's taking a little more research than I expected.

Hoosier Daddy said:
...and a jet kit if you go with pods. Check out Dynojet http://www.dynojet.com/jetkits/ I bet their "SUZ 83 GS450 STANDARD FLOAT" is close, certainly worth a call!
Click to expand...

Would I really want to get a jet kit so similar to what I already have in there?
 
So got back to work on the bike tonight after traveling/being sick/generally blowing it.

Can anyone confirm the outer diameter of Mikuni BS34 carbs? I still haven't ordered pod filters and forgot to measure how large I need 'em.

I spent most of the night pitting my walnut-sized stegosaurus brain against the electrical system. I'm trying to reassemble the signals/headlamp/etc. and have some major wiring error. I labeled all the connections as I disconnected them up front, so I think it's gotta be something next to the battery.

My battery was all but drained, but when I tried using 2 alternative batteries, there was a lot of sparking and even smoke, so I backed off. Does anyone have a photo of the stock arrangement of the electrical panel on a GS450? I checked against a wiring diagram, and it seems like I have it all in the right place, but obviously something was wrong. I guess I have the "later style" relay from the GS450 series.

Electrical systems were my biggest worry to begin with and I'm not sure how to troubleshoot this. Any help would be MUCH appreciated. Thanks.
 
Dunno if this is all you're looking for but here's how mine's set up. You might note I've got a different flasher relay for my smaller turn signals (Lower Right)
IMAG0220.jpg
 
That's great, thanks. Where do your positive wires run from the battery?

I have one that plugs back into a connector, then into a fuse, and continues on (I'm pretty sure) to the starter motor. Where does your second wire connect? It looks like it's supposed to be somewhere on the starter relay but I'm not sure where specifically I should be fixing that little washer/lead.
 
Battery positive should not go directly to the starter. Should go to the solinoind THEN to the starter. Othewise your starter would crank at all times because the circut is completed as the starter itself is grounded to the engine case.
The other positive wire from the battery most likely goes to the fuse panel.
 
Hoosier Daddy said:
Battery positive should not go directly to the starter. Should go to the solinoind THEN to the starter. Othewise your starter would crank at all times because the circut is completed as the starter itself is grounded to the engine case.
Click to expand...
Roger on that. I have two positive wires off the battery. One uses a connector and then continues on to the solinoid/starter/etc. The other just has one of those washer-type connections, and I screwed it into the wrong position when reattaching it.
elec_panel.jpg

That's where I had it and clearly that was incorrect. So now I'm trying to figure out where it bolts on.
 
IMAG0225-1.jpg


I've got the two wires from the positive lead on my battery. The thicker one goes to the circled nut on whatever that thing is, solenoid? The thinner wire goes to the fuse and up under the seat towards the front of the bike, I'd imagine to the ignition system somewhere.
 
Got the front-end electrical straightened out last night. My flasher relay is kaput (signals switch on, but are constant rather than flashing), so I'll need to order another one.

How she'll look until I get around to the seat:
2012-04-11_21-16-39_489.jpg


I went through tightening everything on the front end, and I've definitely got some extra line in both my throttle and clutch cables. I'm going to relube the clutch cable tonight and see how much that helps, right now it is a bitch and a half to operate. I've been reading up on shortening the cables, but since I don't have any soldering tools, it's kind of a ball-punch. Maybe I can find some online.
 
There's a video on YouTube where the guy uses his barbecue grill to heat it up and just touches the solder to that. I'll see if I can find it but its what I've been considering, even with superbike bars the clutch is super stiff and doesn't let out til the levers nearly completely out.
 
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