1981 GS450E Rebuild

[Guest]

Cheers Don, that's great, and I won't tell anyone what you did with your left 'bar switchgear

I originally was thinking of my brother's GPX750 choke lever that's on the left 'bar and rotates around the bar rather than moving left to right like yours. Either way is good for me.

My big issue with it will be working out how to attach the cable to the carbs themselves instead of having to use the lever attached to the side, but that's also the least of my worries at the moment.

 

[SVSooke]

Don:switchgear on the 83 GS750's are aluminum,don't have the pass switch and don't have the press to cancel.Miss that ,the SV had it.

 

[Suzuki_Don]

Cheers Don, that's great, and I won't tell anyone what you did with your left 'bar switchgear

I originally was thinking of my brother's GPX750 choke lever that's on the left 'bar and rotates around the bar rather than moving left to right like yours. Either way is good for me.

My big issue with it will be working out how to attach the cable to the carbs themselves instead of having to use the lever attached to the side, but that's also the least of my worries at the moment.

Pete I also have the answer how to attach the inner cable to the carbs. I will dig out some pics and post back later.

 

[Guest]

Sounds good to me Don! You're just full of helpful advice aren't you

And I appreciate every bit of it

Cheers!

 

[Suzuki_Don]

Choke Mechanism

Choke Mechanism

OK Pete, I think I have got the best pics I can find on this choke mechanism. Now this mechanism is used on all the four cylinders from the latter part of '82 and the '83 models with the CV carbs. The earlier four cylinder GS's used a different leverage type system.

Above: This bracket mounts on the top of carb #3, the choke outer cable fits into the long brass nut thingo, the inner cable passes through the entire setup turning at 90 degrees to run parallel to the choke rod and connect into a small mechanism screwed to the choke rod. This bracket also has the part that the throttle cable attaches to. If this is in the wrong place for you then it can be cut off and use your existing throttle mounting bracket. But you get the idea.

If this does not make sense or you can't fathom the pictures then let me know. I know you dont have a #3 carb, that is the way it is set up on the 650s. Just adapt the parts to your two carbs and all should be A-OK.

.

 

[Suzuki_Don]

I originally was thinking of my brother's GPX750 choke lever that's on the left 'bar and rotates around the bar rather than moving left to right like yours. Either way is good for me.

Pete the '93 GSXR750R Suzuki also has the choke lever that rotates around the handle bar.

 

[Guest]

Thanks heaps Don, those pic's are great and I understand exactly how that all works together.

From memory, the 450 choke is on the left hand side of the left carb and rotates along the side of the carb, so that may be a bit awkward in comparison to the 4 cylinder ones.

I'll have to go take another closer look though and compare it with your pic's to see if the same idea will work.

And thanks for the note on the GSXR lever, I might try to track one down to keep it all Suzuki

I need to find a wrecker soon to look for an alternative seat and rear mudguard anyway, so that would be an ideal opportunity to look for a choke lever.

 

[Suzuki_Don]

Yes Pete, I can see how your original choke mechanism works now. That system is similar the the VM carbs, it lifts the choke plunger up vertically rather than horizontal like the 4-cylinder CV bikes. I made a wrong assumption that all CVs would work the same. Sorry 'bout that.

 

[Guest]

All good Don, at least it gives me a look at how one's done as up until now I've only seen the lever on my brother's 'bar (never looked at the carbs behind the fairing), and of course my 450 don't have one.

Now that I've seen that, I can start to get some sort of clue on how I could possibly rig one up.

I'm sure it won't be that hard to make up some sort of bracket to bolt on there somewhere...

 

[Leigh]

Pete, all the GSXFs have that choke lever you want.
I think the Bandits and SVs do too.
Shouldn't be too hard to source.
But I think they are part of the switch block from memory.

 

[Guest]

Cheers Leigh, guess it wouldn't be that hard to replace the whole switch block as long as it has the same functions.

 

[Leigh]

It sort of looks like this one, Pete.

Ebay:

Link 1

Link 2

Link 3

 

[Guest]

Cheers for the links Leigh, I get it now

Only downside with one of those is I lose my headlight switch... don't really wanna lose that as I used to use it every time I started the bike...

 

[Leigh]

Just wire one in somewhere..

 

[Guest]

Got an answer for everything haven't you?

Actually I did think about that after I posted... I wouldn't mind adding a hazard flasher switch just in case also... hmmmm... ideas ideas, but where to put them? Will have to figure that out down the track.

Something tells me getting it running first would be a good idea

I got time to duck into the auto parts store down the road today to get some sealant for the crankcase halves.

So, what I located had best be the ducks nuts/bees knees of sealants...





Why are there four pic's of a tube of sealant?

Because it's $39.95!!! How much? $39.95!!!

As I said, it better be the ducks guts/bees knees of sealants...

 

[Leigh]

Pete, my light switch is on the right hand side.
Is the 450 different?

Hazard lights? Hazards are for Triumphs.
Suzukis don't need them.

 

[Suzuki_Don]

Pete, my light switch is on the right hand side.
Is the 450 different?

Hazard lights? Hazards are for Triumphs.
Suzukis don't need them.

Leigh that's the same switch I have on my 550, it came off an '81 or '82 GS650G (katana I think), must have been common for that year. It gets the ON/OFF switch onto the right hand side of the bars, often needed when doing mods like putting a choke or whatever on the left side.

 

[Leigh]

Don, mine is an '81 750.
I think Pete's is a bit earlier.

Maybe the switches changed over the gap in the years?

 

[Guest]

Hmmmm you know it could be on the right hand side... that's how long since I've used them!

It's an '81 and now you really got me thinking... I have to look tonight.

 

[Guest]

Well this is an exciting non-update...

No cam chain yet, still waiting.

The house mate managed to loan a good quality set of vernier calipers from a guy from his work today so I got to measure my pistons and cylinders and work out that it's all well within spec and I just need standard rings.

Also got some concrete pavers laid on Sunday ready for the garden shed which arrived yesterday, so hopefully this weekend that can go together and I can move a bunch of crap from the garage. That should give me room to move the frame to the other side of the garage which will let me work on the bike at night, which is the only time I can possibly get at the moment.

I'm itching... really itching to get this done! Depending on ring cost though, it's looking like once the bottom end's together that will be it until after Christmas and the Christmas bills are paid... I think I'm gonna struggle to get the cylinders and head blasted as it is.