GS 550E 1980 -cafe build

[wegs426]

So, what's that rear cowl made from?

It's made from fiberglass. I don't have any pictures of the process since my hands were pretty much covered in epoxy and glass.

As for the rear shield, I had intended on using the stock fender but couldn't get it to look right. Now what I want to make is an aluminum fender mounted on the swing-arm.

As for the seat It will be getting a black vinyl cover, with a filler insert upholstered on the rear cowl to fill the hole. Then when I want to carry a passenger I just take off the rear cowl and the seat is twice as big.

Right now I've been enjoying riding it and working on getting it to run better. I ended up having to do the valves. Everything on this forum says that should be the first thing you do when you buy a bike, but I Ignored it at first and it gave me a lot of trouble. It turns out all valves were off, most by 2 sizes and some by 3. It actually idles now.

[wegs426]

(post 1 of 2) Pictures of paint process and recent updates

Primered


White on


Here is where things started to go wrong...
Taped off for some stripes


One of the colors


Less than thrilled at the outcome, I like the colors but the spacing is all messed up.



Restart


Cleared without stripes


Another picture all finished


Went to the Rochester Distinguished Gentlemen's Ride. We got rained out but still had a blast.They had two camera vehicles, still waiting on video.


Even came home with a trophy: Best Bike

[wegs426]

(Post 2 of 2)

Last week I hit a large pothole. My rear shocks didn't decompress afterwards.
The bike was low enough that my solid mounted license plate was scraping on the chain. They measured 11" instead of 13"



I decided to replace with higher quality, no more pogo sticks.
I went with 360mm ~14.25" significantly longer than stock.
It was a long week of waiting but they finally came today.


Here they are next to the compressed shocks!


Fitted


Look at that stance.


Took it out for a ride and it is a whole new bike. Bumps don't want to buck me off like before, it feels so much sportier in the corners as well.

Issues: I still have to get used to putting my feet down further. It leans over on the kickstand much more, I'm thinking of bending it out?
Chain is a bit looser that I like, at times it rubs on the swing-arm. I may have to get a tensioner or a plastic wear guard.

[headsbikesmopars]

What part number for the K&N filters on your 550 ? They have to be SHORT to fit in the limited room behind the carbs, and yours seem to have space left. VERY nice build , very nice. Thanks .
Terry

[wegs426]

What part number for the K&N filters on your 550 ? They have to be SHORT to fit in the limited room behind the carbs, and yours seem to have space left. VERY nice build , very nice. Thanks .
Terry

Thanks, I actually had to try twice to get them right. The number is: K&N RC-2550. They fit really tight in diameter but it is the only filter I know of that will fit the small 550 frame.

[headsbikesmopars]

THANK YOU VERY much..that solves a fitment problem for me. I have an '80 GS550E modding out too. Watching this closly. Very good write up. Thanks.

Terry

[wegs426]

With winter in full swing here and a break from classes I have begun to dig into phase II.

rearsets: I purchased some '86 interceptor brackets.

I browsed forever trying to find a suitable bracket, one that would match the slope of my frame, look good, and have passenger foot pegs. I plan on drilling the front peg and mounting DCC universal rearsets to these. I still have to buy one side as I encountered a scummy ebay seller. I also need to fab a steel bracket and weld it to the frame.

I also came across this ' 83650g on craigslist around thanksgiving.

No title, and cheap. I have already sold the seat and recovered half my purchase price!
Now I can join in on the recently popular 673 top end swap.

Started the tear down.


Got the motor out 2 days ago. I never realized how heavy they are, made me realize that we are basically riding around on an engine with wheels on it.


From here I need to take the motor apart and see what shape it's in before I tear out the 550.

I would also like to use the forks from the 650g so I can use the dual discs (eventually do a salty monk upgrade). I am not sure if there are differences between the 650e and 650g forks. I don't want to put on lesser components just because I have them, I would rather wait and buy 650 or 750e forks if necessary.

As for the 650g I haven't had much interest in other parts from it. It's not really in great enough shape to do a quick spruce and sell. I'm currently toying around with the idea of putting the 550 block on it if it's possible. Maybe doing a scrambler style build, not that I need another project/moneypit...

[wegs426]

I've made a bit more progress on the build since last time. Not a lot of physical work but lots of researching and part finding.

Finished tearing the 650 down


Nothing but a frame a box of parts, wheels and motor.


Parts from the 650 that I will be using on the build.
Carbs: These are in great shape so I'll refurb. them and get a dynojet kit.
Forks: I want to use the lowers so I can go dual disc but I'm having trouble finding a diagram to take them apart specifically the top.


Everything I need from the motor. Very minimal carbon deposits too.


Leftover bottom:


Wrestled the 550 out:





I'm still figuring out gaskets, ignition and cams on the motor. I want to run the 550 cams in the 650 head but don't know how this works with the bearings.

[wegs426]

I managed to get the 650 forks all apart, there was a ring in the top that couldn't be seen or removed unless you push down on the recessed top cap.

Also got my Dime City Cycles order in. Rear sets, linkage, and passenger pegs.


Had to modify the bracket a bit to hold the pas. peg but got one mocked up.


Also got my mikesxs cartridge emulators.


Just have to get the 550 forks apart and figure out what to do for springs.

[wegs426]

Just a little disc upgrade completed.


Drilling rotors to fit bolts:


EBC contours for cbr600, together they weigh about the same as the one 550 rotor and are about the same size, they are much larger than the 650 discs.


Next up: Splitting cases on the 550.

[GateKeeper]

Love the rotors.....wouldn't mind doing that to my 750.....can you share from where you got them and how much.....

the foot pegs were another item I was going to do while I was doing my rebuild, maybe this season I will go for it....

.

[wegs426]

I got them from ebay for an expensive $390. Saltymonk found out that the 99-00 Honda CBR 600 F4 has the same bolt pattern which is helpful if you're buying new. They are EBC contour part number MD1014XC.

Love the rotors.....wouldn't mind doing that to my 750.....can you share from where you got them and how much.....

the foot pegs were another item I was going to do while I was doing my rebuild, maybe this season I will go for it....

.

[wegs426]

Splitting cases on the 550.
Started by removing side covers. NOte it is best to drain the oil prior to engine removal as most did not come out of the drain plug and made a mess of my bench.


For some reason I thought I had points but this looks like electronic with an advance unit. I guess thats why I never had to adjust points. Looks like I won't have to switch the ignition from the 650.



I thouht I could keep the pan on but off it came to get at more bolts


Finally separated, totally amazed at how well they stuck together.


Started grinding the casing to make way for the larger 650 sleeves, almost got it all the way in. Also any tips on removing crankshaft seals?

[Nerobro]

This is very much the hard way. :-) Neat to see though. The 550 ignition works fine with the 650 top end. It is an electronic ignition with mechanical advance.

[wegs426]

Haven't made too much progress these last few weeks, but I did get a nice Miami vacation. Now that I'm back in the tundra work shall continue. Before I left I finished clearancing the casing to fit the block. I was hoping to get my forks finished also. I drilled the damping rods as required for the mikesxs emulators.


Then I went to install the racetech springs only to find out they were slightly too large in diameter. I've heard that others have had this issue as well. So I placed my order for a set from sonic which are slightly smaller diameter. They didn't have as still I would have liked but its close (.80 vs .85 kg/mm).

Today I fitted the springs and set the preload, when I filled it up with oil I realized that my seals leaked. I guess when I seated them with a socket and a clamp it ****ed them up. So now I have a new set of seals an a seal driver on the way. Lesson learned

So instead I started to strip some paint on the engine. This stuff works much better in my dads warm woodshop than it does in my frigid garage.


Also detailed the lettering on one of the tires. Looks good but it will be interesting to see how long it lasts.