81 550T winter redo

[Loki]

So time for some winter maintenance and such. Bike is an 81 550T, runs and drives well. I have owned the bike about a year and am the 3rd owner. The main reason for the tear down is to fix some oil leaks, one from the base gasket at the #1 cylinder forward edge and another leak at the head gasket between #2 and #3. I figured I would take the down time and freshen up a few other things.

When I first got the bike it had been sitting, only 100 miles or so had been put on it the previous 2+ years. I cleaned the carbs and installed new orings, adjusted and synched. Other than that an oil change is about all that has been done to it.

Here is a list of things I would like to accomplish during the winter, any tips, pointers, comments and or suggestions would be great :

Replace all top end gaskets, I have gathered all oem parts

Replace intake boot orings

Adjust valves

Replace piston rings - compression readings were 128, 131, 130, 134 dry - figured since I was in there might as well, pending inspection once disassembled

De-carbon the pistons, head and cylinders

Replace front and rear fenders with chrome

Paint tank and side covers as paint is faded, clear coat flaking off - thinking of black without pinstripes

Polish the case covers, front forks, etc.

I'll post some pics as I go, here is a "before" shot, disassembly in works

[gearhead13]

Are those compression numbers on a warm engine with the throttle wide open and a fully charged battery? Valve lash adjusted?
Best way to really get the head clean is to fully dissasemble it and get it hot washed at an engine shop.

[cowboyup3371]

Great looking bike if I don't say so myself. Where did you find the backrest/luggage rack? I'd like to get one for mine but haven't seen anything yet. Good luck and keep up the posting; I'm starting to do some work here too.

[Loki]

Are those compression numbers on a warm engine with the throttle wide open and a fully charged battery? Valve lash adjusted?
Best way to really get the head clean is to fully dissasemble it and get it hot washed at an engine shop.

Yes, compression check was done after a 30 mile ride, throttle wide open, battery fully charged. Valves clearances had not been checked / adjusted in who knows how long. I checked them today during disassembly (all in MM)

Intake Exhaust
#1 .06 .02
#2 .07 .09
#3 .03 .04
#4 .06 .02

A few on the tight side, will loosen them up during re-assembly. Also got the head off, lots of carbon on the pistons and the valve areas of the head, curious to see the amount of build up on the rings and if their moving free. Yes on the head, plan to disassemble it to change valve seals and measure everything up along with a cleaning.

[Loki]

Great looking bike if I don't say so myself. Where did you find the backrest/luggage rack? I'd like to get one for mine but haven't seen anything yet. Good luck and keep up the posting; I'm starting to do some work here too.

Right back at ya', nice color that grey is. Thought about going with a gun metal but leaning towards black with more chrome and some highly polished goods. I work on aircraft for the j.o.b. so polished metal is a mainstay

The back rest / luggage rack came with it, no idea who made it. It "appears" to have been on the bike a long time though, same amount of rust as other parts, etc. The po had no idea as it was on it when he got it.

[cowboyup3371]

Right back at ya', nice color that grey is. Thought about going with a gun metal but leaning towards black with more chrome and some highly polished goods. I work on aircraft for the j.o.b. so polished metal is a mainstay

The back rest / luggage rack came with it, no idea who made it. It "appears" to have been on the bike a long time though, same amount of rust as other parts, etc. The po had no idea as it was on it when he got it.

Thanks but it's pretty nasty looking up close. I'm thinking of turning the bottom end into all black with the top side blue with a black stripe. Still working on it but I'm pretty close to being set. Just need to wait for spring time to come first.

[Loki]

That sounds like it would be great looking. Are you talking flat black or glossy on the bottom? This one has a nicer back rest with what appears to be a removable luggage rack I think, i see the brackets for it. Mine is fixed, can"t remove it unless I modify it

http://cgi.ebay.com/ebaymotors/Suzuki-GS-GS550-SUZUKI-GS550-GS-550-CAFE-RACER-STOCK-NJ-MINT-BUY-NOW-_W0QQcmdZViewItemQQhashZitem3cb2f16e3fQQitemZ260700204607QQptZUSQ5fmotorcycles#ht_1639wt_1165

[Loki]

Some more pics, just after the valves were checked and then as the cylinder bank, jugs, unit removed. As I suspected the top rings are gummed up pretty bad, cleaning all this up gonna make her run like new. Taking into account the lack of use the last few years and recent long term idle / low rpm times with my lady learning how to ride have fouled things up

http://i822.photobucket.com/albums/zz144/livinonklandathu/Teardown009.jpg

http://i822.photobucket.com/albums/zz144/livinonklandathu/Teardown015.jpg

[Loki]

So, during the winter months, got it all broken down, cleaned up, measured everything per the manual and am in the process of putting it all back together. The valves and seats are fine, lapped them back in. The cross hatch still visible in the cylinders from new, amazing the lack of wear overall. Ended up plastic bead blasting the head, turned out really nice. The tank, and side covers I sanded and gave to a friend to paint and they look awesome with PPG airplane paint applied and 3 coats of clear over the top, did just plain black on all. I'll post pics tomorrow as the re-assembly goes on.

[Loki]

Well if mother nature would cooperate I could finish this thing. No heat out in the shop and it snowed 4+ inches yesterday. Pic of the new paint

[IMG][/IMG]

[Loki]

And one of the re assemble. All went back together good except had an issue with a cam journal cap bolt, broke off flush while tightening so had to pull the head again and dremel it out, put in a new heli-coil and good to go.

[cowboyup3371]

Nice looking paint job on the tank Loki, I hope mine turns out that nice. I hear you on the weather - went from 60s earlier this week to 50s yesterday and I don't think we climbed above 40 today.

[Loki]

Nice looking paint job on the tank Loki, I hope mine turns out that nice. I hear you on the weather - went from 60s earlier this week to 50s yesterday and I don't think we climbed above 40 today.

Thanks, I cant take credit for the spraying as the pros did it . I see your tank is coming along nice, looks good so for with the prep and all. Finally got it running today, fired right up. Gonna do a nice ring run on it tomorrow if the weather holds

[Loki]

Still cleaning and polishing to do. Not sold on the chrome fenders either, maybe a bit to "L" looking, dunno yet I'll see if they grow on me. Opinions welcome

[Loki]

Finally got some time to finish the cleaning and polishing of the forks, covers etc.




And installed a small Maier fairing