81 GS550T Full Rebuild...In Ohio

[cowboyup3371]

Thank you Ed. I was thinking about that over the last few weeks but I need to make some sign to reinforce the idea before I leave the garage. In fact, I put oil in it the other day and it was at a decent level right now for what I needed to do today. However, after shutting it down I realized I needed to add a bit more before I try to start it again. Once I tighten both wheels down hopefully tonight I'll pull it off the blocks, put it back on the center stand, and then get it done.

[Guest]

Feels good to hear that engine running no? A nice encouraging sound to help push you through to the end and create some excitement. Can't wait to see her with her new clothes on. Keep plugging. You are oh so close!

[tkent02]

Suggestion from experience: before you take that first ride double every fastener you can reach with a wrench. Wheels, forks, brakes, handlebars, EVERYTHING. Sometimes over the course of a year in the garage some things get overlooked.

Scott, I would ask someone like Steve to do this with you.

It's important.

[cowboyup3371]

I sure am learning what I don't like about powder coating. I stopped over at the garage tonight and adjusted the clutch the best I could after replacing the nut on the end of the adjuster. I then attempted to put the gear shift lever back on but the dang thing wouldn't slide into place very well thanks to the powdercoat placed there earlier this year. After taking the file to the post the lever sits on and sliding it back and forth I finally got it to sit properly. If I ever have to powdercoat a frame again, I'll make sure I do any taping, masking, and plugging of holes to ensure I don't run into the same crappy work these folks did. I'm also hoping the circlip will stay in place like it should as I couldn't find the groove it's supposed to sit in.

Front brakes are also in place as well as a new speedo cable I finally found. I ordered a new battery today as well as adjusted the chain.

What's left to do?

Finish sanding the tank and side covers
Make the new brackets for the rear turn signals as I'm missing one and the other is badly rusted
Mount the rear signals
Connect the wiring in the bucket
Recheck and tighten all bolts
Put cotter pins in places they need to be
Fill the brake reservoirs and bleed the brakes
Find the tags for this year and put on the license plate
Find a new hose clamp for the rear brake reservoir to master cylinder hose
Ziptie the wiring harness to the frame
Clean off the dust from the frame from sitting this last year
Fire it up again and go ride

That's about all I can think of for tonight although I'm sure there's more to do. A couple of more weeks should about do it if I can just get that tank done. The nice thing for this week at least is I have no reason why I can't make it to the garage - the kids are on fall break. I still have swim lessons Monday and Wednesday to get one kid to but otherwise no homework commitments

[Guest]

Awesome news she's running Scott, real glad to hear it!

[cowboyup3371]

Remind me never to paint my own project again. Using the block helped me create an edge and go through the paint near the front of the tank. My friend says we can just feather and fix the paint when we are done but we have a long way to go still. I'm hoping for a ride and might do so before the paint is finished but am still debating on that since I am also waiting for a piston cup set for the front master cylinder.

[Guest]

Doh!

[cowboyup3371]

Rebuilt the front master cylinder and rebled the brakes but they still don't feel perfect even with the fact there's no air coming through any of the lines. However, they still seem like they were last year so I'll make sure my first ride will be to a parking lot to check them out.

Also installed the rear turn signals and reterminated the ends but just as I was trying to run the wires through some shrink wrap this morning, work decided to call me in. Afterwards, my daughter had swim practice then the eldest had a Ohio Music Education Association Marching Band State Finals competition today where the team won a Superior rating (highest). I'm hoping I'll be able to go over to the garage tomorrow after doing some more work troubleshooting a phone issue we've been having with a vendor. Seems only the government cares enough to observe Veterans Day but as we've been fighting this problem for some time I felt we should get it done while the vendor was willing to work with us.

I'll probably forgo finishing the paint issues until later this winter so I can get a ride in before the weather gets too bad. So, just know what pictures I can take are not going to be great.

[Guest]

No worries. Not too many of our projects here are perfect anyway. So post 'em up and let us enjoy!

[Guest]

Scott, did you see my tip in the wrenching thread? Strap that brake lever back to the 'bar overnight and you should have a nice firm lever in the morning.

[cowboyup3371]

I'll give it a try Pete if I can make it back over to the garage tonight as I'm just now logging into work (love VPN systems - can do it from home). My only concern with that is how we didn't find any air in the system so I'm not sure if that will help. Not to mention this is a Kawasaki MC and not a Suzuki so will it act the same way?

[tkent02]

Scott, did you see my tip in the wrenching thread? Strap that brake lever back to the 'bar overnight and you should have a nice firm lever in the morning.

This works very well, but not if there's something wrong with the system.

[cowboyup3371]

Seals and pistons in both front calipers were replaced this time as well as the piston set in the MC. Like I said, I'll give things a try here as soon as work stops being a pain in my arse. Course, I could always go back to a stock Suzuki setup as I think I still have the calipers in the storage shed.

[Dogma]

Seals and pistons in both front calipers were replaced this time as well as the piston set in the MC. Like I said, I'll give things a try here as soon as work stops being a pain in my arse. Course, I could always go back to a stock Suzuki setup as I think I still have the calipers in the storage shed.

That would be a lot of work to find out what regret feels like. Even if the lever doesn't feel perfect, I bet it's still far better than stock.

Does the caliper still slide on the pins, or is it pushing the disc before the lever firms up? Come to think of it, I need to ask myself this question. After the wreck, I imagined the lever felt slightly mushier than I thought it did before. It still stops on a dime, but any sense of "not right" with the front brake is worth looking into.

[tkent02]

Can't remember, what brakes are you using?