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Help with a GS450 1982

  • Thread starter Thread starter WoodenPlanks
  • Start date Start date
Ok, so I started rebuilding the carb to soak them, with the help from your walk-through. (Thanks!) And the needle jet is stuck in the float bowl.
I am afraid I tried using pliers gently but ended up scarring it a little and it still wont come out.

Any tips?
 
WoodenPlanks said:
Ok, so I started rebuilding the carb to soak them, with the help from your walk-through. (Thanks!) And the needle jet is stuck in the float bowl.
I am afraid I tried using pliers gently but ended up scarring it a little and it still wont come out.

Any tips?
Click to expand...

Good job on tackling the carbs properly.

In case you didn't know, cycleorings.com has a kit for the 450. I think they have the intake boot O-rings too (please don't skip these).

If that needle jet doesn't come loose after soaking, try hitting the carb body with a heat gun. Heat will melt the varnish holding the parts together. What ever you do don't force anything.

Good luck and keep going...
 
Yeah that's was I was hoping for...
cycleorings is great, I am awaiting my order from the site and I'll rebuild these things right.

I will be changing my intake system to K&N and my exhaust will be a free flowing system. So, taking pete's advise I will order a main jet three sizes up from 115 to 130 and the pilot from 45 to 47.5? Is that correct??
 
Good stuff, cycleorings is definitely worth while.

Don't just take my word on the jets, go here and read, this is where I got it from:

http://www.motorcyclecarbs.com/

You may find other more useful info therre too.

Are you still stuck on the needle jet? I got stuck on that too, but letting WD soak into over night was all it needed. I was able to grab it vertically with needle nose pliers and gently but firmly rotate it left to right and pull it out. I did get a couple of scratches on one where the pliers slipped at first, but just surface scratches, no damage at all.
 
Great thanks for the resource, he has some good tips on there.
I decided to soak the float bowl with the needle jet stuck in it. hopefully it will break it free.
I have been looking everywhere for a replacement needle jet but can't figure out the style it is. The manual lists the size O-6 but no style number.
 
Just an update:
I have been taking parts off, cleaning them up. Removed the headlight ears and replaced them with chrome ones. I have been looking at these 2 into 1 exhaust systems online. What do you think? Rejet? Again? haha...
Oh and by the way while taking off the exhaust, one of the bolts snapped...****. I have an extractor set but I am curious if you guys have any tips. I have been soaking it with WD40 for the last couple days hoping to free it up a bit.
Thanks again
-AJ
 
Do some searching here and you will find tons of threads about broken off exhaust bolts.

A common permanent fix once they're removed is to put studs in instead of bolts.

Depending on the 2 into 1, it may not need rejetting as a lot (Motad is one I know for sure) are designed to be a direct replacement for the stock exhaust.
 
Do a search on removing that broken stud. I've read about using reverse drill bits being much better that extractors.

cg
 
I got the new bars some clip ons, and a new tank, GS450E.
I have mostly been polishing up some casings and cleaning up the bike, I'll post some photos in the next couple days.

I was curious, if I want to put some spoked wheels on this bike what should I be looking for, in terms of hubs. I found some rims that look nice.

Also, what size studs am I looking for to replace the exhaust bolts? I did a search but couldn't find anything...
 
Last edited:
Nice one, looking forward to the pic's :)

Not sure on the wheels, but as for the studs, the standard bolts are 8mm x 35mm long going by the Suzuki part number (01500-0835B). Typically the second part of the part number for bolts is the thread diameter (first two 08) and thread length (second two 35). I believe their 8mm bolts are 1.25 pitch but you would need to confirm that.

I'd start by sliding something very thin into the bolt hole and measuring how deep it goes.

To that measurement, I'd then add the width of the exhaust flange, and then allow enough for a nut and lock washer to thread on and tighten up.

Make sense?
 
Perfect sense!
Thanks

Anyone know of an online resource for something like this?
 
Last edited:
Haha, great Pete.

I'm sure they will have something and if not I could buy some longer ones and cut em down to size.
 
Yeah true, and now that I said all that, I'm thinking I should probably do the same for mine. I already know a good fastener place just near my house mate's work too. I need to replace my exhaust bolts anyway because they're quite rusted and I don't want to use them again except for the first test firing with the old exhaust.
 
Did you ever get the needle jet out . Mine was glued in and tryed to pull it out with pliers and destroyed it . Then on the other side I noticed you can hit it out with a screwdriver and hammer if your careful and is much easier all around .
 
I didn't want to push it too far with trying to get it out. I soaked it sprayed it, hopefully it will be enough. I already rejetted my carbs and put them together but if I have to change some jet sizes I'll make sure to get that little guy outta there.
 
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