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GS450 Surreptitious Engine Reassembly

On a whim I loosened the bolt which applies a spring-loaded nub into the shift hub, something clicked. I now can shift into all the gears, except...neutral? :confused:

Gonna fire her up tomorrow morning.
 
She fires up, leaking fuel bowl and the other usual annoyances to deal with after cleaning the carbs (I had the engine apart, so why not).

Bigger issue: shifting is very difficult, it seems I do not have a neutral in spite of the indicator light saying so, and some gears seem to actually fight the engine when I start letting out the clutch. Needless to say, didn't run the engine long.

(sigh) can someone shed some insight on what's up? I don't want to have to take the engine all the way out but it's starting to look necessary. I never touched the transmission much, may have bumped it while fishing out the crankshaft. What could be wrong?

Also, I don't know how to confirm that the oil pressure is good to the head.

I'm glad she runs though.
 
What about the shift mechanism behind the clutch? You might want to check that out.
 
Well, everything seemed correct on the gearshift mechanism. I've matched the shift mechanism behind the clutch as best I can to what both suzuki and clymer manuals specify. I verified this last night, that I can grab the arm attached to the shift rod and kind of shift between a couple of gears. But no neutral even though the shift hub is positioned correctly?

Something ain't right.
 
Phew. Long day yesterday, removed engine, split case, found I'd acctidentally reversed a gear in the transmission, reassembled case, remounted into engine.

My back is sore :P

Anyway, I'll give her a test tonight or tomorrow once everything else is mounted back up.
 
Status update: she's been running pretty well these past few weeks, though seemingly burning a bit of oil. Spark plugs look ok, light dusting of carbon and no wet spots. No blue smoke out the tailpipe, but there is a small amount of blue smoke coming from the exhaust headers. I've washed the bike, and can't determine a source for oil.

I'm thinking to work on the top-end now, I bought a bottle-brush hone, new top and base gaskets+o-rings. Perhaps I'll lap the valves as well. Any other suggestions on things to consider working on with this?
 
If you're going to do all that, may as well do new piston rings and replace valve seals (since you're taking valves out to lap them anyway). And If I'm not mistaken, a common source of the smoke you see at the headers could be valve seal related.
 
Hey Rich, forgot to mention that I got some OEM rings as well. With the hope, of course, that there are no gouges in the cylinder walls..

Any recommendations on seals? Leaning towards OEM, though I see some new Viton aftermarket types.
 
Last edited:
Sorry, haven't done this work myself yet. Just things I've tossed around in my brain and read about at this point.
 
Nessism said:
Viton valve stem seals are good.
Click to expand...

Ed, were those the blue viton ones you've seen? What's a good source?

I wound up ordering OEM NOS since I'd like to do this work come the weekend, but I'm likely going to do this step once again for my 1000.
 
Thanks for that fastbysuzuki, I'll look into that for the 1000 I'm bringing up. What were the OEM seals made out of?
 
I am not sure what the original's are made of but I do know they are not Viton, Viton is a superior material than the Oem.
Fitted them to my 850 around four years ago had no problems.
 
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