1978 GS550 Custom Build Project

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  • Urban Monk TV
    • Jan 2026

    #1

    1978 GS550 Custom Build Project

    Hello All. I've been lurking on TheGSResources for years now. Thanks for all the wonderful insights over the years. I've owned my 1978 GS550 since Spring of 2015. In November of 2016 I decided to tear it down, rebuild the top end and rebuild it custom as a cafe racer. I have documented the entire thing in a video documentary series on YouTube in case any of you are interested. The focus has been to show the detail that is needed for a novice to do this work on their own bike. I've learned some things about making videos along the way and quality improves over time. I hope some of you enjoy.

    Episode 1. Tear down.

    Last edited by Guest; 03-04-2019, 07:19 PM.
  • Urban Monk TV

    #2
    Episode 2. Continue with tear down.

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    • Urban Monk TV

      #3
      Episode 3. Engine removal.

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      • Urban Monk TV

        #4
        Episode 4. Removing the tappet cover, gathering tappet clearances, removing the cam chain tensioner, checking cylinder compression and removing the cams.

        Last edited by Guest; 03-04-2019, 05:13 PM.

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        • Urban Monk TV

          #5
          Episode 5. Remove cylinder bank, inspecting camshafts, checking them against service limits, and removing stubborn screws from the intake boots.

          Last edited by Guest; 03-04-2019, 05:13 PM.

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          • Urban Monk TV

            #6
            Episode 6. Remove the cylinder bank and determinewhether he needs to bore for oversized pistons or can stick with standard size.

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            • Urban Monk TV

              #7
              Episode 7. Removing pistons from connecting rods.

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              • Urban Monk TV

                #8
                Episode 8. Stator, clutch and starter cover removal.

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                • Urban Monk TV

                  #9
                  Episode 9. Remove starter, ignition points, advance and measuring clutch disks.

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                  • Urban Monk TV

                    #10
                    Episode 10. Cleaning up the engine. Rust removal. Stripping clear coat.

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                    • Urban Monk TV

                      #11
                      Episode 11. Replace oil filter cover stud. Prep engine for painting. Inspect transmission gears and dogs.

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                      • Urban Monk TV

                        #12
                        Episode 12. Painting engine.

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                        • Urban Monk TV

                          #13
                          Episode 13. Clean pistons.

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                          • Urban Monk TV

                            #14
                            Episode 14. Install new piston rings. Install pistons. Hone cylinders.

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                            • Urban Monk TV

                              #15
                              Episode 15. Painting cylinder bank and installing.

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