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1978 GS550 Custom Build Project

  • Thread starter Thread starter Urban Monk TV
  • Start date Start date
U

Urban Monk TV

Guest
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.

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

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

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

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

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

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

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

 
Episode 16. Rebuild cylinder head. Valve lapping. Remove valves and springs.

 
Episode 17. Install valves into head and head onto cylinders.

 
Episode 18. Install the valve tappet buckets, shims, cam chain guides, and camshafts.

 
Episode 20. Install valve shims and polish alluminum stator cover.

 
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