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Waking up an old GS450

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Update:Got disgusted with the old harness so we replaced it. The right cylinder is still dead so I'm leaning toward a bad coil. Still no lights, a freind of mine is suggesting dirty contacts in the ignition switch for that. She cranks only when she wants to, clutch in or out--I thinking of a bad switch there. Any thoughts or suggestions as to whether or not I'm headed in the right direction?
 
You can bypass the clutch/starter interlock switch or whatever it's called. The two wires from the switch on the bars go into the headlight bucket and connect to the harness. Disconnect the switch and connect the two wires from the harness together. Remember to have the bike in neutral or clutch pulled in when you start it!

I would also clean the contacts in the starter button, the connections for the heavy wires going to the starter motor, and the connections to the starter relay (solenoid), which is the gizmo the heavy red wire from the battery is connected to.
 
Can't bypass the clutch switch because of inspection regs. I'm going to try pulling the switch apart and cleaning it. The key switch part is what's bothering me. It makes sence that bad contacts could cause these problems, but it sounds too simple.
 
They do get gummy. I had to jump the S off the relay for a while until I actually pulled the starter switch apart and cleaned it. You might be able to bypass it just to see if that is the issue.
 
snark said:
Can't bypass the clutch switch because of inspection regs. I'm going to try pulling the switch apart and cleaning it. The key switch part is what's bothering me. It makes sence that bad contacts could cause these problems, but it sounds too simple.
Click to expand...

These bikes aren't shuttle technology, but they are 20+ yrs. old. I cleaned my clutch switch, wasn't hard just be careful pulling it apart. If I remember correctly there are little springs under the contacts that can get lost. The hi-lo switch is even more complex, has springs and balls under the contacts.
 
IanFrancisco said:
If I remember correctly there are little springs under the contacts that can get lost.
Click to expand...

Been there... done that....

On that side you could easily loosen the control box and flip it upside down to keep those little bits from falling out and find the nearest same colored crack top fall in.
 
bgmart450 said:
IanFrancisco said:
If I remember correctly there are little springs under the contacts that can get lost.
Click to expand...

Been there... done that....

On that side you could easily loosen the control box and flip it upside down to keep those little bits from falling out and find the nearest same colored crack top fall in.
Click to expand...

That is a good tip! I have come close to loosing the spring in both the clutch switch and brake switch. Spent about a half hour looking at the ground under my bike the first time I took one apart.

I'd leave the exhaust alone unless you have to take it off, but here is what I did to get a broken exhaust bolt out...If you can remove the exhaust you can try either vice grips on the small bit of bolt sticking out or using a dremel or similar tool to make a slot for a screw driver. I'd get some good penetrating spray, like WD-40 but better. Can't remember the exact name but the guys at any autoparts store should be able to recommend something if you don't already know what I am talking about. The vice grip trick worked for me after I snapped the head of one of the bolts.
 
The turn signals now work. Any advise on the horn? The handlebar switch box was replaced with one from Ebay and it seems to be working fine. I've tried a spare horn that I know works with no luck. Is there a seperate ground for the horn I may be missing?
 
Fuse block

Fuse block

I had to put a new fuse block in my '80 GS850G after it sat in a junk yard outsdie for two years? I could tell casue it got REAL hot to the touch when running! :cry:
 
There is just one fuse on the bike. I've traced all of the wiring and am still stumped!
 
Update:
She's almost ready to ride! The only things left are a front brake light switch and ANOTHER ignitor. The guts of the switch just plain were missing and the replacement ignitor was dead. As soon as the new parts come in, she'll be on the road.
A note to anyone trying to bring one of these back to life...no matter how bad it looks, it IS possible. If I can ever figure out how to post pictures to this sight, I get some up. You'd be amazed at what we started with.
 
ITS ALIVE!!!!
She went for her first ride in years around my yard tonight! Once the plates come she'll hit the streets. It was spuutering alittle when the choke was taken off, but I think that my be just a little carb cleaning issue. They were cleaned but there may be alittle bit of gunk that just needs to be blown out.
 
You are about to start saving a lot of money on gas! :wink:
 
I've already be riding mine...$5 a week instead of $30 for my truck. The friend of mine that I fixed it for is looking forward to riding it.
 
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