Suzuki GS450 Cafe Racer Motorcycle Build: Components
A few years ago, I purchased a 1981 Suzuki GS450L. It was rough running and in overall mediocre shape although it was basically complete. I gave it a little TLC and put a few hundred miles on it over a few years. The only modifications made was to add K&N filter pods and Dime City mufflers. I updated the jetting with a lot of trial and error. It still isn't perfect, but runs well enough to get around, if a bit on the loud side. The plan from the start was to find a middleweight bike (for back in the day) that wasn't pristine, because I wanted to custom it as a cafe racer or bobber. Having a bike in less than great condition would be ideal so I wouldn't feel bad for tearing down a perfectly good bike. I finally finished up some other projects around the house so it's time to get after the bike build.
My plan is to go with a blacked out color with little to no frame cutting so most updates would be bolt on. Below is the basic component list and links (some are affiliate links) to parts I used.
Electrical
Lighting
Brake System
I started off by installing a new brake rotor. The old one had some grooves and pitting. It could have been used, but new drilled rotor would be a nice upgrade visually and for braking performance along with new pads. I also got a new brake master cylinder from eBay for a cleaner look.
Controls
The bike originally had cruiser style bars which you can see in the Tear Down article. The handlebar was changed for a simple drag style bar. Grips were updated with nice Biltwell grips which are soft and comfortable. The throttle and cable were worn and were also replaced.
Suspension
The fork seals were leaking, so they definitely needed to be replaced. A full article and video is available on how the forks were shortened. For a bit of protection and classic look, fork gaiters were also added. I'm still experimenting with fork oil weight and levels.
Engine/Exhaust
Body
The mirrors were changed to universal bar end style. They work well, but take a more purposeful glance to see behind than stock mirrors. I have a chin spoiler that hasn't been installed yet. I purchased an old seat from eBay to reshape and recover. It is a work in progress. Lots of learning.
