1980 GS450 "Sport". The grandaddy to the GS500.....Done!

[Big Rich]

Thanks Pete! I'm actually working on rebuilding another set of GS500 carbs right now, and they are getting the works: new o rings, soda blasted exterior, boiled in water, soaked in carb cleaner, new jets, etc, etc.. The current carbs just got a quick "blow out the passages with air and cleaner" cleaning. You're probably correct about that pilot jet though: the current one might be too lean for a 500cc motor, but it does seem to work just fine so far with the 450.

[Big Rich]

Forgot to post this earlier: I took the mag wheels off and mounted up some spoked wheels. They have Kenda dual sport tires installed for my trip to Mid Ohio next month.

[peteGS]

Thanks Pete! I'm actually working on rebuilding another set of GS500 carbs right now, and they are getting the works: new o rings, soda blasted exterior, boiled in water, soaked in carb cleaner, new jets, etc, etc.. The current carbs just got a quick "blow out the passages with air and cleaner" cleaning. You're probably correct about that pilot jet though: the current one might be too lean for a 500cc motor, but it does seem to work just fine so far with the 450.

Cool Rich, are the other carbs from a newer model or anything?

[bryan88]

Really nice work! A GS450 was my first road bike, will always have a soft spot for them. How did the carbs work out? I recall my local dealer saying you have to change the rubbers too?

[Big Rich]

Thanks Bryan!

The carbs are working out well - I don't have a single complaint. I got "new" intake boots and orings with the carbs and haven't had any issues. I say "new" because they aren't 33 years old like the originals. I recently found out though the the stock 450 intake boots are identical as far as I can tell though. The stock GS450 throttle cable needed to be swapped out for a GS500 cable due to different travel on the carb end, and the air intake sides between the two models are different as well - so I had to use filters for a GS500 (makes sense, huh?). Other than all that, I just followed the jetting on the wiki here and have zero issues.

[Big Rich]

Well, the air box is going to have to go on the back burner for a while. I took a day to try and nail down the jetting....and the box imploded before the end of the day. The problem I was having has to do with the physical side ofthe air box & frame: I need the largest internal volume I can get, but am limited on how to get that volume in & out ofthe frame (any larger than what I had would mean literally pulling the head off the motor to get the air box in). So for now, it's a K&N lunchbox filter and earplugs.

And as a side note, I started buffing the paint on the tank and quarter fairing, only to realize I didn't use enough clear coat. So I'll be spraying more of that over the next couple days.....

[Big Rich]

And the winter upgrades begin......



I'll give more details later, but this is where I'm at right now.

[dB-tje]

You did a great job working on this bike  I like it.

[Big Rich]

Thanks DB! That's quite a compliment after seeing your work. 

I have some other minor things to work on over winter, but the wheels / suspension are the most noteworthy.

[Big Rich]

Speaking of wheels:



Polished the lips and painted the rest with gold Metalcast paint. Also installed new bearings after the paint fully cured. Over the next couple weeks I'll rebuild some forks with .85kg Sonic Springs and 15w oil. I still need to order up some Avon tyres too......

The fender got painted red to match the rest of the bike:

[peteGS]

Spot on Rich, those should look good on there in the gold 

[Big Rich]

Thanks Pete! I was surprised when my wife complimented the wheels - she always thought my red body work with gold wheels looked silly. She doesn't understand that red and gold makes a good 10hp!

I'm excited to get this thing back on the ground (so I can work on other projects....). Gotta get those forks done and get the tires mounted first.

[steezin_and_wheezin]

Great work Rich! I normally don't like polished lips, but those are going to look great with the current scheme

[The Buddha]

Whaaa ... gs450 had a twin disk FE ?
Cool.
Buddha.

[peteGS]

Thanks Pete! I was surprised when my wife complimented the wheels - she always thought my red body work with gold wheels looked silly. She doesn't understand that red and gold makes a good 10hp!

I'm excited to get this thing back on the ground (so I can work on other projects....). Gotta get those forks done and get the tires mounted first.

Hahaha yeah I can't get a compliment on mine either! Keen to see her done and back in one piece 

[Big Rich]

Thanks Steezin! I don't like polishing wheels at all, but I hate trying to scrub them when they get dirty even more. At least polished aluminum wipes off fairly easily.....

Nah Buddha, the stock front end on a 450 is pretty weak. Single solid rotor, 33mm forks, and a  3.00"-18" tire. I had a dual disc front end laying around with 35mm forks so I bolted it on. The 500's wheel and rotor are an upgrade all around: modern tire selection, less unsprung weight, etc.

[Big Rich]

Got some work done on the front end last weekend...... first was the Sonic Springs rated for .85kg:



Tore apart the stock GS500 forks:



All assembled with new seals, 15w oil, new springs, and polished lowers (I use the word "polished" loosely......more like stripped the paint and shined up the aluminum):



Overall pic from the other side (sorry about the mess!):

[Big Rich]

Oh yeah - just ordered a front tyre tonight (Avon Roadrider, 110/80-17") but I won't be able to order the rear for a couple weeks. Once it gets both tyres mounted up, I will need to set the preload / sag on the front end. In the meantime though, I got a box of goodies from Adidas: hand controls, miscellaneous cables, clutch perch, etc, etc. I'll be wiring all that stuff in and hooking up the proper cables while I wait for the rear tyre. Still need to get the front brake sorted out as well since I can't roll the bike off my workbench with no brakes......

[peteGS]

She's really lookin' good Rich! Can you ride in winter where you are or too much snow? Can't wait to see her standing on her own rubber again...

[adidasguy]

That work bench wouldn't  happen to be a section of a bowling alley? Sure looks familiar.