An absolute beginners guide to a 1980 GS550 engine

[eil]

Did I read that right, you bought brand-new cases because you couldn't clean the old ones to your satisfaction?

That valve spring compressor might work. It's certainly the cheapest one I've seen. You can go cheaper and pick up an 8" C-clamp from Horrible Freight and cut a window into a piece of PVC pipe or an old socket. (I used an oxygen sensor socket on my 850, but I don't know if that's too big for the 550.)

That valve shim tool is the right one.

I can't imagine how you've managed to disassemble the engine so far without an impact screwdriver!

Search the forum for threads on case sealant. There are many options, almost any will do.

As for cleaning the gears, solvent of your choice followed by compressed air should work fine. If they look clean, then they probably are. In the future, don't leave a disassembled engine hanging out uncovered in the garage.

Crank and gears should drop in to the new case, but follow the manual and measure everything, especially bearing clearances.

[Nbing]

Nope, I had to get a new case because it was cracked. Took it to my dad's friends shop to get it welded and didn't have any luck. I'll post pics of the cracked one tomorrow. Bike must have gotten in a crash because even the tank was dented before restoring it.

[eil]

Ah, okay. That makes more sense.

Get your base and head gaskets from Suzuki. You can try your luck with aftermarket gaskets just about anywhere else. They're fairly easy to change if they do leak. Check out the website for Z1 Enterprises, they tend to stock decent aftermarket stuff for your bike.

[charnotx]

Sorry to revive an old thread... I guess this engine build stalled??

[roeme]

...if not abandoned altogether.