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    550/650 upgrade/conversion

    Hey there everyone. I’m having a difficult time using the search feature to find a good thread with instructions to modify/upgrade/convert my ‘78 550 to a 650 top end.
    I know there’s got to be something in this forum or out on the ol’ interwebs, but I cannot find anything really good.

    Can anyone send me a link, please?

    I need to know how to go about it. I’ve got my 550 engine completely split and tore down, so I figured since I’m rebuilding from scratch, I might as well upgrade to keep up with my buddies.

    Thanks in advance!
    Last edited by Gumbo76; 02-19-2021, 11:04 PM.
    ‘79 GS550
    ‘82 GS650G

    #2




    An old member here named Suzuki_Don made an epic thread detailing his conversion. Unfortunately, I can't find it. If you did around in the archives long enough it should show up though.
    Ed

    To measure is to know.

    Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

    Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

    Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

    KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

    Comment


      #3
      Ah, try searching on "Suzuki_Don". There are tons of hits specific to the 550/650 conversion.

      Good luck
      Ed

      To measure is to know.

      Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

      Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

      Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

      KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

      Comment


        #4
        Awesome! Thanks guys!
        ‘79 GS550
        ‘82 GS650G

        Comment


          #5
          Good luck! The 650 is supposed to be a great match of power & weight so I imagine it will only be better in the 550
          1980 GS1000G - Sold
          1978 GS1000E - Finished!
          1980 GS550E - Fixed & given to a friend
          1983 GS750ES Special - Sold
          2009 KLR 650 - Sold - gone to TX!
          1982 GS1100G - Rebuilt and finished. - Sold
          2009 TE610 - Dual Sporting around dreaming of Dakar.....

          www.parasiticsanalytics.com

          TWINPOT BRAKE UPGRADE LINKY: http://www.thegsresources.com/_forum...e-on-78-Skunk/

          Comment


            #6
            So I searched for Suzuki_Don and it looks like he only has 1 post. Been a member since 2019. Is there another Suzuki_Don?
            ‘79 GS550
            ‘82 GS650G

            Comment


              #7
              Type "Suzuki_Don" in the search field and hit enter. His old login expired and the new user with the same name is not linked to his old account.
              Ed

              To measure is to know.

              Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

              Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

              Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

              KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

              Comment


                #8
                Yeah it's a bummer that the names time out here... I think that should just be taken permanently...
                1980 GS1000G - Sold
                1978 GS1000E - Finished!
                1980 GS550E - Fixed & given to a friend
                1983 GS750ES Special - Sold
                2009 KLR 650 - Sold - gone to TX!
                1982 GS1100G - Rebuilt and finished. - Sold
                2009 TE610 - Dual Sporting around dreaming of Dakar.....

                www.parasiticsanalytics.com

                TWINPOT BRAKE UPGRADE LINKY: http://www.thegsresources.com/_forum...e-on-78-Skunk/

                Comment


                  #9
                  This may or may not help.

                  In the 1978 version of the Clymer GS550 manual, Chapter 11 deals with Performance Improvement. It discusses, and shows, increasing the displacement to 590cc or 740cc.

                  I haven't gone down that road, but the chapter did help me improve my front shocks!
                  sigpic
                  '77 GS550B
                  '78 GS550C

                  Comment


                    #10
                    I've not long done mine, and it's all on my blog with pictures etc.

                    Here's a link to the first post where I strip it, there's a few posts related. Oh, and the difference is phenomenal. This bike is so torquey now and goes anywhere in top gear!

                    1996 GSF1200 — Pretty Much Standard.
                    1983 GSX750ES — Cafe Racer Project
                    1980 GS550E — 673 Conversion.
                    1980 GS400 — Cafe Racer???

                    http://biketech7.blogspot.com.au

                    Comment


                      #11
                      What an amazing write-up! Thank you for taking the time to put this out there for peeps like us who are trying to do the same! I picked up a donor 650G, and just got it running. Want to make sure it’s a suitable donor before ripping it apart.
                      I’ll be referring to your blog regularly as I continue my journey through this project! Thanks!!
                      ‘79 GS550
                      ‘82 GS650G

                      Comment


                        #12
                        Thank you for the compliment!
                        1996 GSF1200 — Pretty Much Standard.
                        1983 GSX750ES — Cafe Racer Project
                        1980 GS550E — 673 Conversion.
                        1980 GS400 — Cafe Racer???

                        http://biketech7.blogspot.com.au

                        Comment


                          #13
                          Basically you just need a custom thicker base gasket or head 650 gasket,
                          Use only GS550 or GS650E cam sprockets, 650G cam sprockets are not compatible with the chain drive cranks,
                          & you need to clearance the cases for the 650 cylinder sleeves to fit.
                          I built one but the engine is sitting on the bench as the wife had 3 other bike projects she wanted done 1st, and the 550 is still 548cc...
                          550 carb jetting obviously is a bit off for what the 673cc GS650 top end needs
                          '77 GS750 920cc heavily modded
                          '97 Kawasaki KDX220R rugged terrain ripper!
                          '99 Kawasaki KDX220R​ rebuild in progress
                          '79 GS425stock
                          PROJECTS:
                          '77 Suzuki PE250 woods racer
                          '77 GS550 740cc major mods
                          '77 GS400 489cc racer build
                          '76 Rickman CR1000 GS1000/1100
                          '78 GS1000C/1100

                          Comment


                            #14
                            FYI look at the 650 frame (or 450, 750, 850, 1000, 1100) & weld on some frame spine bracing that those havebut the 400/425 & 550 are lacking, it'll make it handle way better. The braces behind the ignition coils.
                            '77 GS750 920cc heavily modded
                            '97 Kawasaki KDX220R rugged terrain ripper!
                            '99 Kawasaki KDX220R​ rebuild in progress
                            '79 GS425stock
                            PROJECTS:
                            '77 Suzuki PE250 woods racer
                            '77 GS550 740cc major mods
                            '77 GS400 489cc racer build
                            '76 Rickman CR1000 GS1000/1100
                            '78 GS1000C/1100

                            Comment


                              #15
                              Suzuki_Don's build thread is difficult to search for also because the title is not for a build thread themed topic, it's the troubleshooting/aftermath of his first 550/673 build attempt where he was trying to troubleshoot a knocking noise... That ended with the discovery that the deck heights were somehow slightly different, and the hybrid build required him to custom cut a base gasket out of thicker than stock gasket material in order to not have the pistons smacking lightly against the head...
                              '77 GS750 920cc heavily modded
                              '97 Kawasaki KDX220R rugged terrain ripper!
                              '99 Kawasaki KDX220R​ rebuild in progress
                              '79 GS425stock
                              PROJECTS:
                              '77 Suzuki PE250 woods racer
                              '77 GS550 740cc major mods
                              '77 GS400 489cc racer build
                              '76 Rickman CR1000 GS1000/1100
                              '78 GS1000C/1100

                              Comment

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