Names Aries, St. Paul Minnesota. Project: Cafe build on a 1981 GS450E

Aries

New Member
1981 Suzuki GS450E

GS450E_BEFORE_1.JPG


This is the bike before I wrenched on anything. It was purchased for 600 dollars just this past December. It is great physical condition, however the engine needs a rebuild. I plan to go a few steps further... Will be taking plenty of photos, reading lots of posts on here.

I am doing this project from a Studio Apartment with no power tools, no garage, and pretty basic tools. So if posts are slow to be added, you will understand why.

If you have any info on this model bike, advice or anything you want to share, please message me.

TON UP and Take Care!
~Aries
 
Nice place to start, aside from the motor rebuild.....

Start a build thread! And take a look around at all the other 450 builds here, and on the GSResources.
 
Welcome.
Beautiful bike to start with. Hopefully the engine rebuild will be a mild top end only. Looking forward to where you take it.

Gary
 
Thanks guys, the guy who owned this bike before me said it was leaking oil. I guess he tried to re-gasket the engine by himself with no prior experience and botched the job. It ended up leaking worse then before and then ended up with a charging problem and he tossed the bike in storage. I am going to go over the engine internals sometime in March, make sure everything is clean and good. Make sure there is no cracks or extreme wearing or issues and finish cleaning and polishing the engine case. Gasket it all back up and have a new charging system and electronics and see how it goes. I am a noob to wrenching, but I am patient and calm. I don't mind reading about something a few times, asking advice or waiting and saving for the right parts. I will check out the other gs450 builds.. and GS bikes on here.

Thanks for support!
 
It doesn't sound like it needs an engine rebuild if all that is wrong is that it leaks oil. Determine where the oil leak is. If it is just the cam cover, don't tear the engine down. Just pull off the cam cover. Use some common sense and don't see how deep you can get in over your head. Make sure it isn't just spewing oil out of the head breather, which normally goes into the now non-existent airbox.

Get an Electrosport stator AND REGULATOR for it. Much better than stock.

I notice it has no airbox or pod filters. You need to put decent pod filters on it and rejet. You will need at least a 130 or 135 jet to go with good pods. If you don't rejet, you will ruin the engine. They run too lean as it is.

This is a really nice bike just like it is. There are not that many of this model out there. Please don't fuck it up by turning it into some sort of "custom" monstrosity.
 
Alpha is right. I started out with cheap pods. Worst mistake on these carbs ever. I am sitting around a 135 on mine now with K&N filters and 1 removed baffle on the pipes. There is an article outlining why you shouldn't use the cheap filters on here. It is a very informative read and explains much better than just saying "DON'T DO THAT".
I was able to use them on my xs11 without issue, but on my 450 i couldn't get it tuned even close to right until I Followed Apha and Big Rich's advice on the filters and jetting.

Just my 2 cents to "hopefully" let you avoid a PIA issue.

Gary
 
Yeah, those really cheap pods partially block some ports in the opening of the carburetor, and you just won't ever get them to work right.

The stock jet is 115, and people lose their shit when you say go to a 135! It really DOES make that big of a difference when you take out the highly restrictive air box these bikes were equipped with.
 
Agreed. I was so used to the up two scenerio that when you said 130-135 to me origionally I thought you had lost your mind. Now I know your only paritially crazy..LOl :p

Gary
 
@AlphaDogChoppers;@gk45011

Thanks guys,
I appreciate your experience and advice. If this would have been the S model, I probably would not have even touched the bike except to find someone who could restore it to a "like new" condition. Recently a guy in Minneapolis posted a 1971 CB750 K1 for sale. He had a few things done to it, but it had some top end issues. He posted it for 750 dollars... I looked at all the photos and actually told him.. "yes, I will buy this bike from you..., but man... honestly if you love that bike you should do it some honor and sell it for a little more money to someone who knows what it is for, worth, and will love it as much as you do" I then told the guy to Email Carpy over at cb750cafe.com and tell him what was wrong with it and ask him what he should sell it for. I once started a build on a 78 cb750... Carpy wrote me a few times when I was asking for advice. Nice guy.. Anyways... I guess the point I am making is I do know that respect and honor goes into motorcycles and they are not always just to be torn down and chewed up.

Whatever work I start on this project is going to be finished, and work. I am not going to take this bike down to parts and get stuck.

The main reason I got on this site was to talk to people like you and hear your feed back and take in your motorcycle wisdom. I tried going down this road earlier in life thinking I could just do it without help or advice and that was the most ignorant attempt I had made at anything mechanical.

I still have the airbox, the guy I bought it from had it removed and the exhaust too. His exact words were "it leaked from the side of the engine, me and a friend tried to put new gaskets on it and it ended up leaking worse. it also isnt charging right anymore" I asked him if he road the bike daily before that and he said yes. He was a nice and easy going kinda guy, but he was not a mechanic and I could tell that he was not experienced at working on motorcycles.

I am prone to make "new builder mistakes"... so that is going to happen, but I will be wrenching on this thing until it is road worthy before I even sit on it. I feel in many ways that I have to earn the right to really be a part of this Cafe Racer culture and a motorcyclist. Many of my friends who own bikes, buy brand new and have no idea what anything does. It breaks and they store it until they can fix it or they sell it. I can't help but want every little drop of the motorcycle feeling to be part of me. So... Please keep the advice coming, I actually had sent off a request to a company to make me a new set of Jets a few weeks ago.. they asked me my altitude, make and model and what modifications I had made to the bike. I told them I was replacing the airbox with after market filters. I just got the package today and its out in my car. I will go get it in a few minutes here and post a photo and some info. Could be another waste of money. I saw a set of Stock carbs on Ebay last night that looked in AMAZING condition for a little over 85 dollars after shipping and was tempted to get them for a back up.

I knew before starting this project that I was most likely going to spend more money then I planned. If money was the main concern, I would not even started this project... it is one of the issues, but the main thing for me is the general task of bringing this project to a realistic state of completion. I am just going step by step, and piece by piece.

Thanks again guys!
 
Aries, seriously: start a build thread.

There are a lot if details and input that many people could give you. And some of us have stock GS450 carbs around that would sell for less than $80......(ahem).
 
@ Big Rich

Thanks, I will start a build thread very soon. I am have taken alot of photo going over all the work I have done so far and I am going to organize the photos into ones I want to post, put them in order and sit down and make sure I start the thread right. This is my first time being part of an online forum or community and I have little experience with posting. I am tempted to sit down and study how to write and respond to posts.
 
Here is the Carb Kit I got. Until just now, I did not know what I was getting. It might not end up working, or it might be a bit over my head. I might end up needing to get a stock set of Carbs, or figure something out, but at any rate, here is a photo of what I got. This all will go into a build thread.. I am just posting it here as response to the mention of Carbs in earlier post.

P1020773.JPG


P1020775.JPG


One major reason I took this on again... a project.. a build.. was the experience of learning what works and what doesnt. I expected to spend alot of money on mistakes, but I knew I was not just buying a mistake, I was buying the value of learning from the mistake. If these do not work, I will be ok with that.. most likely a deep breath and shake of the head.. but I will be ok
 
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