GS450 "Sport" - Done!

Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Big Rich said:
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.
Click to expand...

I used a Bandit 600 wheel on my GS.I had to have my friend machine new spacers and we had to widen the rear swing arm to get it in.We used a Katana caliper hanger machined down to get the caliper back down on the Bandit 600 rotor.I had to space out the GS500 cush drive to keep from offsetting the rear wheel while keep the sprockets inline.My addition to the original write up is down this page. http://gstwins.com/gsboard/index.php?topic=27757.0
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Good info Ben! Thanks.

I don't think the GS450 will accept that large of a tire though. The "L" model had a 120/90-16 tire, so a 130/70-17 isn't really stretching it at all. I figure a 140/70-17 would be the largest I might go with, and it's just about perfect with the Bandit 400 wheel.

Ben you probably know this: how well does the straight spoke (98-02?) Katana front wheel fit in GS500 forks? I've read that it fits with some minor modifications, but have no idea what those mods are......
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Big Rich said:
Good info Ben! Thanks.

I don't think the GS450 will accept that large of a tire though. The "L" model had a 120/90-16 tire, so a 130/70-17 isn't really stretching it at all. I figure a 140/70-17 would be the largest I might go with, and it's just about perfect with the Bandit 400 wheel.

Ben you probably know this: how well does the straight spoke (98-02?) Katana front wheel fit in GS500 forks? I've read that it fits with some minor modifications, but have no idea what those mods are......
Click to expand...

It's a direct fit for the GS.All that's need is transferring over the hub cover from the GS wheel when running one rotor and new GS wheel bearings.It's the little plastic thing on the left side of the wheel.It covers and protects the bolt holes for the missing left rotor.If you're going dual disc,then it doesn't matter because it won't be used.I don't know how you're gonna run twin brakes on a GS front end unless you use two right side forks.
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Thanks! I had just read somewhere that there were some modifications necessary, and nobody went into detail as to what they were. The 450 will be getting the single caliper setup from the 500 for economical reasons.
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

You're welcome Rich.
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Polished lips, gold paint, new wheel bearings, etc.....



And the GS500 fender got some love too:



Oh - next week I'll be doing the forks, then eventually getting tires mounted.....
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Been reading thru your post quite some times now,and i have to say that i am really impressed of your knowledge!
What type of wheels are these white 3 spoked ones (bandit 400?)?
I`ve been trying to lace the Rm-wheels for a few days (first time ever),but with no luck :'(
(So they are now living behind the shed again!) Might try this option for my 78 400
Great inspiration Rich!
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Front is GS500/89-97Katana Rear is Bandit 600 and is a rare 4.5 inch swept spoke wheel.Most swept spoke wheels are 3.5 inch and come from GS500 or 89-97 Katana.

20131102_030536_zpsdbf2a1cc.jpg
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

(sorry for jacking Rich)
if i choosed to go with 3,5 both front and rear,would that hurt my handling in anyway?
I`m gonna run these in4.00 both front and rear:
 

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Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Oh fancy.
Lets see em mounted!
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

JustinLonghorn said:
Yep.
Click to expand...

I'm going to call you Ducky from now on.
Yep yep yep
http://www.youtube.com/watch?v=cAEVzJnHv2c
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

THanks, I am having flashbacks to watching this over and over and over with my little cousins while babysitting.
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

JustinLonghorn said:
Quack.
Click to expand...

You see sir, thats the genius. Ducky isnt a duck! who'dathunkit.



And now sorry for the hijack Rich, lets see some cool shit.
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Thanks gents. That's all the cool shit I have until next week though (back to work tonight). I mounted the front rotor this morning and didn't take a pic of it. One concern that might come back to haunt me though: the wheel bearings I bought were from an eBay seller called "Boss Bearings" or something. Once the axles were installed, the balls in the bearings felt unusually tight - as in the wheel was slow to spin freely. So I "might" be replacing them with some AllBalls bearings later.

Ben / Floegstad - the rear wheel is actually a Bandit 400 wheel, not a 600 wheel. I actually bought it from Dgyver. But give me a couple hours and I'll look into what tires those are recommend wheels to fit.....
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

THANX in advance! :)
 
Re: GS450 "Sport" - Yep.......progress. Resto-mod just went out the door.

Floegstad, who makes those tires again?
 
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