1982 GS450t cafe

[Poopwink]

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 the left-hand side of the motorcycle? I checked against a wiring diagram, and it looks like I have it all in the right place, but obviously something was wrong. I guess I have the "later style" relay.

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.

 

[Guest]

All the size details you should need should be here:

http://www.knfilters.com/search/product.aspx?Prod=RC-1822

Just take your time with the electrics and trace the wires according to how they're laid out in the wiring diagram and you should be good as gold.

 

[jeffasaurus2]

Sent you that picture of the stock electrical set-up for the 450 on Do-The-Ton, didn't realize you'd made your way over here yet!

 

[ndaugbjerg]

Poopwink,
Thats going to make a neat cafe when your done. Your excitement and enthusiasm reminds me of myself 50 years ago when I was rejetting and putting a straight pipe on my 3-1/2 Hp. Allstate(Cushman) scooter. Stick with it and don't get impatient.
Niels

 

[Poopwink]

Thanks all. I've rebuilt/restored a few classic Porsches with my pops but this is my first motorcycle build and the first time I'm "leading" the project. These forums make life a lot easier..even 15 years ago it must have been so much tougher without this kind of access.

I'm trying to move by sections to pace myself. I'm trying to finish the front end (which, right now, means wiring in the new signals and getting new brake pads). Then it'll be carbs/filters/exhaust time, followed by cleaning the rear and installing the rear signal set I put together. The weather's finally getting nice up here, which makes me A) want to ride and B) want to avoid the garage and enjoy being outside again.

 

[kirkn]

Hey, looking good.

If you're not going back with that stock rear grabrail, I'd sure like it. Mine was missing when I got it.

Thanks,

Kirk

 

[Poopwink]

If you're not going back with that stock rear grabrail, I'd sure like it. Mine was missing when I got it.

Kirk, I'm pretty sure I'm abandoning that grabrail. Do you have any spare levers/perches you might want to trade? :lol:

Got the front-end electrical straightened out last night. Felt good to fiddle with the controls and see it work. Ahh, progress.

I'd like to shorten my clutch cable because in its current configuration it is a bitch and a half to operate. I'm looking into ways to do it myself but most of the options seem to require tools/equipment that I don't have access to.

Here she is now.

 

[ndaugbjerg]

Poop and Kirk,
Both bikes look great. Shame we are not all closer because it looks like we are putting together a fleet of good lookin' twins. Later on, we'll have to figure a way to put together a photo rendezvous.
Niels

 

[ChicagoBob]

Nice-looking bike. If your clutch cable is binding, try looping it around the right side of the steering head, so it doesn't bend too tightly. If you need the cable to angle more to the front, so the loop is a gentler radius, try a GS500 clutch lever assembly - fits your bike, but the cable takes off angled away from the bar, rather than parallel to it. They are often available on eBay.

Also, it doesn't hurt to lube the cable, especially a new one. That helped a lot with my cafe 550 (on which I am using a GS450E clutch cable).

 

[Poopwink]

Nice-looking bike. If your clutch cable is binding, try looping it around the right side of the steering head, so it doesn't bend too tightly. If you need the cable to angle more to the front, so the loop is a gentler radius, try a GS500 clutch lever assembly - fits your bike, but the cable takes off angled away from the bar, rather than parallel to it. They are often available on eBay.

Also, it doesn't hurt to lube the cable, especially a new one. That helped a lot with my cafe 550 (on which I am using a GS450E clutch cable).

Yeah, I gave it a half-assed lube yesterday but will try again tonight and see if it makes much of a difference. The clutch lever was already crazy stiff when I picked up the bike, and with the clip-ons I just have too much cable--not sure how much a forward-angled cable assembly would aid this problem.

I'll try going to the right of the steering head and try and mellow out the curvature on this thing tonight. Thanks all.

 

[jeffasaurus2]

Let us know how that works out for you, I've got the same issue with mine, just gotten used to it.

 

[Poopwink]

Got the rear signals and tail light working and mounted! Not sure if I'm going to keep the tail light here or move it a little lower and further under the seat. Overall pretty happy with how it worked out. I think it's a considerable improvement over the enormous stock set up and was pretty cheap.

I tried my stock flasher relay with the motor on/off, and also switched over a stock relay from an '81 CM400 but didn't get any blinks. Got a no load/electronic one (I guess those old stock relays were load/thermal) for $9 from the local auto parts place. Thanks again, Jeff.

I've been trying to work in sections, so now I'm really diving into cleanup down below and around the seat pan. All kinds of dead beetles, spider egg sacs, etc...

I've gotten her some fresh air and fired her up a few times now. Starts every try, but idles a little rough. I'm waiting on a front wheel spacer that disappeared before I can start riding her around. Installed new brake pads last night. Slow but steady progress!

 

[ChicagoBob]

Looks very nice and racy. You can get a matching black clutch lever from Mike's XS for about six bucks. It'll bolt onto the GS clutch lever bracket.

 

[Poopwink]

I've been slowly chugging along at this project and have hit a few speedbumps:

Bouncing idle. I don't think it's the actual throttle cable sticking, it's gotta be something in the carbs. I checked my boots and while they're old, I think they're still good.

I threw the boots/carbs/filters back together and was working on building my own manometer so that I could perform a sync...but now my petcock isn't functioning properly.

It won't feed fuel into the carbs. I disassembled it and looked for buildup/corrosion and didn't see anything that looked problematic. I was able to start the bike a handful of times because there was still a bit of gasoline in the carburetors, and that should at least start pulling fuel, right? There was nothing coming down the line, so the idle kept dying.

The petcock won't feed fuel from ANY position, regardless of whether the bike is running or not. Any idea what to do next?

 

[Guest]

I've been slowly chugging along at this project and have hit a few speedbumps:

Bouncing idle. I don't think it's the actual throttle cable sticking, it's gotta be something in the carbs. I checked my boots and while they're old, I think they're still good.

I threw the boots/carbs/filters back together and was working on building my own manometer so that I could perform a sync...but now my petcock isn't functioning properly.

It won't feed fuel into the carbs. I disassembled it and looked for buildup/corrosion and didn't see anything that looked problematic. I was able to start the bike a handful of times because there was still a bit of gasoline in the carburetors, and that should at least start pulling fuel, right? There was nothing coming down the line, so the idle kept dying.

The petcock won't feed fuel from ANY position, regardless of whether the bike is running or not. Any idea what to do next?

If your boots are old, the O rings underneath will be equally as old, and I'd suggest replacing both.

You can get a new fuel tap/petcock for less than $80 from Boulevard Suzuki, but I'd check your vacuum line and connection first and also pull the tap out and check the filter for crud build up.

Does your fuel tap just have on and reserve? If so, you'll have a little brass screw beside it which is for priming. Turn that on for about 30 seconds and see if it fills your carb floats. That will tell you if fuel is able to get from the tank to the carbs, and will narrow it to a fuel tap or vacuum connection issue.

 

[Poopwink]

Does your fuel tap just have on and reserve? If so, you'll have a little brass screw beside it which is for priming.

Mine's got three settings: PRI (prime), FULL (default), RES (reserve). I disassembled the petcock and tried to clean out any residue or buildup but there actually wasn't any.

I'm going to try again after work and see if I somehow missed something obvious.

 

[Guest]

Mine's got three settings: PRI (prime), FULL (default), RES (reserve). I disassembled the petcock and tried to clean out any residue or buildup but there actually wasn't any.

I'm going to try again after work and see if I somehow missed something obvious.

Aaah ok, you have the other style of tap to mine.

Put it on PRI if you can and see if that allows fuel to run...