81 GS450s - lets see if she'll run after sitting for 2 years

[Anonymous]

OK...so I got motivated this weekend and figured I would try to get my 81 GS450s running after it had been sitting for 2 years. A friend of mine gave me this bike along with it's "evil twin", the same exact bike except it's a track bike(that's been in my basement for about 4 years but supposed to have a better engine). Here is a pic of the street version:

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I checked out the air filter and installed a new battery. I removed and lightly cleaned the carbs, they appeared to be pretty clean. I put the key in and the instrument panel lights up, but nothing else works. Horn, starter, headlights, turn signals all don't work. I know it's probably something simple but to be honest I am pretty new at troubleshooting electrical systems. Here is what I started fumbling with today...I broke out my multimeter and started testing. I tested the battery, the main fuse near the battery, the kill switch...was busted but I hard wired it for testing, and the clucth switch. Everything up to that point seemed to test out ok.

Anyone have any ideas?

 

[SqDancerLynn1]

Did you check the saftey switch on the clutch lever. Manny New GS owners don't realise it is there Didn't read far enough Go Back and check for 12 V on the kill switch, Check for 12V on one side of the start switch, check that the 12V is being applied to the starter Soloniod when the start button is pressed

 

[Anonymous]

The kill switch has been bypassed and the the clutch switch has been checked. I am getting 12V on the other side of the switch and the starter button. I will have to figure oout where the starter solonoid is before I check that. :lol:

 

[Anonymous]

Get the Clymer book if you don't already have one. Or check this link for electrical diagrams: http://smokeriders.com/index.html

Don't know what would have exactly those symptoms other than broken wire supplying those components: starter relay, headlight, etc.

I've worked on mt 450 a fair bit. Let me know if you need tips. Some things I know and others I don't but I'd be glad to help.

So... tired...

Later...

Michael

 

[Anonymous]

Thanks Michael! I hope to get a chance to start following some wires and looking for breaks this afternoon.

 

[bgmart450]

You might try jumping the solenoid with a screwdriver to see if it will start.

The solenoid is on the shifter side of the bike under the side panel and looks like this: (mostly its under that finger)

To jump it take a screwdriver and connect the two posts on the solenoid. (or is that the relay? or are they the same thing?)

 

[Anonymous]

Thanks bgmart, I will give that a try.

Edit: Well that worked no problem. The engine tried to turn over. Now I have to figure out what's broken in between.

 

[bgmart450]

I am lucky enough that I was easily able to tell it wasn't the relay. We have 2 450's and I was able to swap them.

But at least you can tell that most things past this relay are ok, its either the relay or something before. Mine was the actual starter button. It was very rusty, a lttle sandpaper to clean the contacts and we were good to go.

 

[Anonymous]

hehe...well I did take my starter button apart...now I have to figure out how to put it back together. Darn small parts and springs and such! :wink:

 

[bgmart450]

haha, yeah its pretty funky. Its button, cap then spring. When the spring compresses the cap makes contact with the part inside the grip.

Here 5 - 11 is the spring 4 - 10 is the cap and 3 - 9 is the button

Not the clearest of images, but I hope that helps

 

[Anonymous]

Thanks Brent...when I first put it back together I had the cap in the wrong place. I took the horn apart to see how it worked.

I still can't figure out why I have no lights. I've been trying to seperate that issue from the actual starting issue. The way I am figuring it is I should have lights whether or not the bike starts or not. I need to figure out what the lights (front, back, and blinkers), horn, and start button all have in common. Am I right in trying to break this troubleshooting up? I dunno but I'm gonna try my hardest to find out!

Edit: Is there more than one fuse one this bike? I can't seem to find any more than 1.

 

[bgmart450]

Yeah, one fuse.

I am betting getting a wiring diagram would help you out a lot here. I have the Haynes manual, but no scanner... Unless you are getting a manual soon or someone can beat me with a jpg of it I could copy and mail you a copy of the wiring diagram for your bike. Just send me a PM if you'd like a copy.

 

[Anonymous]

Brent..thanks for the offer. I think I am going to try and find a manual. I had heard the Haynes one was better for this bike, but not sure about how reliable the source was. If anyone has one they want to get rid of let me know.

Earlier in the thread Michael suggested I check out a website for a wiring diagram...I found this, but I am not sure if it's correct it wasn't listed under the twins and I kinda thought the 450 was a twin. I'll have to look at it more closely.

Thanks again!

 

[Anonymous]

Hmmm...this little gremlin doesn't want to show his face. Still can't figure out why I have no electrical except for the oil pressure and neutral indicators. I've been trying to use the wiring diagram but havn't had much luck. I'm not sure if I am testing correctly. I have a multimeter and I am measuring for 12V. I started with the battery and tried to move along the diagram. Things which seem to test out ok is the kill switch, the clutch switch, and the start button. That leads me to the orange wire which seems to connect to a boat load of things.

Is it common for there to be a broken wire deep inside the wiring harness? I've inspected the wires where I can see them and unplugged and replugged most of the connectors I could fine. I found a few breaks in the wires that connect to the gear indicator lights, but these probably have been broken since I've had the bike since those lights never worked anyway. I resoldered those wires and taped everythign up good.

Any thoughts, advice?

 

[Anonymous]

Bump Bump...been combing the site and web for some info but not finding any. I'll take anything you have to offer...general electrical troubleshooting tips even a "it's a long shot but try this!"

I think I am getting desperate. :roll:

 

[Planecrazy]

One of the most common electrical problems in a situation like this is a bad connection (which looks fine on visual inspection) and especially a bad ground wire.

I would strongly suggest that even if a connection looks good, disconnect it and clean every wire and contact point. Only then will you know for certain that your connections are good. It is possible for a multimeter to pick up continuity or voltage through a bad connection that isn't allowing enough current to flow in order to operate lights, etc. That's why a thorough cleaning is always a good start.

Good Luck!

Steve 8)

 

[Anonymous]

Ahh!! Progress! It feels so good!

I finally got most of the electrical working. Headlight, taillight, blinkers, gear indicators, high beam indicator, and brake lights are all working. I now need to figure out the starter, which I think I would have if I had not run out of light. Boy I wish I had a garage. The problem I think was a bad ground. I'm not sure, because I think I unplugged and replugged almost every connection on the bike, but the ground was the last think I messed with.

Today Lights!! Tomorrow the world!! ... ok maybe just a bike that will attempt to turn over.

 

[Anonymous]

She runs!! Yes that is right! My bike now starts. Sounds good too...ok good may be too strong of a word, I'll switch it with 'ok'.

New problem, yup now that she is running she doesn't want to shift worth a darn. I felt like I was going to break my toes trying to shift into second...wouldn't budge from foot power. I can use my hand and shift, but it's kinda hard to operate the clutch and reach down with my hand at the same time. So...any ideas on how to make the bike shift a bit smoother....ok 'a bit smoother' is not really going to do the job....how about A LOT smoother?

 

[nabrams]

Congrats!!

I've already restored 2 GS450 bikes from non-running condition to functional daily riders, so I know that great feeling when the bike runs for the first time.
Usually, howvever, it takes at least several more days/weeks to work out all the gremlins after that initial triumph (no pun intended :wink: ).
I suspect that your clutch plates are "glued" together after sitting for so long (search for other posts that discuss this).

I had a 1977 Honda XL350 that needed the following done in order for the clutch to "loosen up":
Change the oil.
Lube and re-adjust the clutch cable to spec.
Started the bike in neutral.
Pull the clutch lever all the way in.
Push the bike along to get it moving before slamming it into first gear (with the clutch lever pulled in).
Withe the clutch lever pulled in, rev the engine to 3000 RPM for a couple of minutes.

If after all that it still won't behave you may have to look into things like bad clutch plates or bent shift fork. But if the bike rode fine before you stored it then I doubt it's either of those problems.

 

[Anonymous]

I can hand shift the gears and all the gears seem to work once I get to them. Is there anyway to test the clutch plates or shift fork? Or are there other common symptoms of either of these problem I should look for?

Thanks!