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1982 GS550M Katana Rebuild

  • Thread starter Thread starter mv577
  • Start date Start date
Been slowly picking away at the bike... work / life has got in the way of my initial pace but things are still coming along... I decided I was going to have the rotors and calipers powder coated instead of painting for durability etc... I stripped the rotors off both wheels...



I then got to dissembling the front calipers... I was worried they may be rusted but turns out they were ok... thankfully.







I then started tearing into the motor...



Which is when I found this damage on the head...





There was a broken exhaust bolt as well so I decided instead of trying to repair this to get a second head... I grabbed one from EC Cycles in Maine who I've bought race motors from in the past... Here's the replacement head they sent... the cams have rusted but I don't need them... the rest of the head looks solid so I'm happy for the $69 it cost me..

 
Started opening up my motor... the plugs didn't look too bad...



Chain tensioner seems to be working as the chain was nice and tight...



Cams out...



First look at the pistons... usual carbon build up... lots of dirt / grim floating around... shop vac'd it as best I could...



Cylinders off...



Hard to tell in these pictures but the cylinders look ok... there was even some crosshatch left... the rim at the top seems to just be carbon...

Free pistons...



Top end in pieces... so simple yet so complex... lol



Pistons removed from the rods...





Aaaand.... a toasty stator...



So I consider myself pretty handy and I've been researching working on the head for the last few weeks... I get the concepts, even though this would be my first, and have gone back and forth about tackling the refresh on my own... in the end though I decided to drop the two heads, the pistons and block off to a local motorcycle engine shop that a good friend has used for years... Although I know I could do the work I'm not 100% confident in being able to know exactly WHAT work should be done... For a couple of extra OT shifts they are going to go through it all for me... and when I get it back I know it will be 100%... even bead blasted ready for paint! piece of mind is worth a few bucks...
 
Parts keep rolling in as well... another batch of OEM bits...



One thing I sourced were European covers for the back of the speedo and tach... The US model are chrome... but over the pond they got ones painted in the same silver as the headlight ring... which I liked a lot!!! I found these NOS from the UK...





It's a little detail but I think it will look good!

Ordered a stainless bolt kit for the engine cases and carbs... again... little details...



My front fender was cracked so I got this Purple Gem from the Netherlands... New paint scheme maybe???? lol



Noticed signs of a crash on the stator cover...



I'll probably try and source a nicer one we'll see... I began trying to clean it up anyway but I know those scratches will always bother me...



Kept poking around the lower end... pulled the clutch cover off to look around... I'll be doing springs and plates... everything looked ok though...



That's about it for now... I need to organize and get a good to-do list going to keep myself on track lol...
 
Nice! Do not be affraid by disassembling all. These engines are very easy to rebuild, everything can fit with "good sense". After having disassembled the clutch, do not hesitate, for your own, to take pictures of the gear shifting assembly. For me this is the most complicated to rebuild if you never toke pictures and if this is your first time.
 
I'm still digging through the lower end of the motor... I pulled the ignition cover off and found it coated in oil... looks like the crank seal is leaking... added to the list..



I also started sorting through my electronics and wiring... My original harness had been hacked a bit so while ordering other parts I grabbed an unmolested harness...



Starting to unwrap the harness for cleaning and rewrap...



Doing some resto work on the ignition switch...







I then started cleaning up the plastic dash / gauge bits...





All painted...

 
Workshop is getting a little messy... but messes mean progress!!



I was able to get my old, cracked tires off the rims... and removed the wheel bearings in preparation for cleaning...



Right now I'm just planning on cleaning and polishing the wheels... I'll see how they look from there... they seem to be in good shape and once I realized they were supposed to be grey and weren't just faded black I think they'll look good...

But the biggest news of the day is.... I got all of my parts back from Powder Coating today!!!!! I'll admit I stood and stared at them for a while... I went with a color called "Parcor Black"... which is perfect... it's basically satin with a fancy name... but it's exactly the level of shine I wanted... love it!











 










So I've never seen one of these bikes in good original condition so I have no real idea the exact color the calipers, rotors etc are supposed to be... I gave my Powder Coat guy the Dupli-Color paint can I planned to use as a reference... He admits, and I agree, that the parts came out a little more orange then the paint... however they do seem to match ok against the Suzuki sticker on my original tank... He's willing to redo if I want... but I'd hate to make him do that if I don't have to... Are the parts supposed to be more red? or more of an orange? Any insight would be helpful :) Either way they look great!!!
 
Last edited:
steve murdoch said:
Nice work on the instrument cluster, Mike.
$150.00 or so for the frame?

After seeing this post from the Kat site, Google Ral2002 blood orange for a color comparison.
http://www.katanaownersclub.co.uk/forum/viewtopic.php?p=36280&sid=76b5084afa040122333d9eb3a5834b80
Click to expand...

Thank you for the color reference... I'll admit I keep forgetting about the Kat site.... and thank you... I'm trying my best to salvage what I can but I don't want it to look off ya know...

I paid $500 for all of the powder coating... I thought that was reasonable given the time saved and the longevity of the finish over paint :)
 
Welcome to the forum. It is always great to see another kat being saved and returned to former glory. Keep up the good work.
 
So while digging through part parts bags I realized I never sent the top handlebar clamps to the powder coater.... ugh.



I'll be dropping those off to be done... while I'm at it I think I'm going to have to get the calipers and rotors done over... I was trying to like the color but it's just too orange... A slight setback but I have plenty to do... I was just hoping to have it in a roller by end of week...

I got some more parts in and have been working to keep it all organized...



Moving on I got the first few new parts on the bike... first up was steering head bearings...



Got to use my new Harbor Freight bearing driver.... worked as advertised lol



Lower race in...



Center stand installed...



On the schematic there was a cushion that looks as though it is meant to stop the stand from hitting the frame... I bought it and can see that one end should be pushed into a hole somewhere... but for the life of me I can't figure out where lol



Any thoughts??? I can't find a hole anywhere to push it in to...

Kickstand installed... hey every little bit helps!!!

 
Got my new tires!!!! I went with Continentals... I've used them before... well not this model... but the brand... always had luck with them.



Next up!!! Swingarm bearings... My shop press came in real handy here... slid right in...





Spacers, washers and dust seals installed ready to be mounted!!! I ordered Hagon Shocks but may mock up the swingarm with the old shocks.... we'll see



Triple clamps installed... I got my Sonic Springs today so I'll build the forks tomorrow...



and as she sits now...



I heard from my motor guy too... looks like everything is in good shape... only a hone needed on the cylinders so I ordered a new set of standard rings... :)
 
mv577 said:
On the schematic there was a cushion that looks as though it is meant to stop the stand from hitting the frame... I bought it and can see that one end should be pushed into a hole somewhere... but for the life of me I can't figure out where lol
Click to expand...

bracket off the exhaust ?
 
That rubber bushing should have a corresponding hole in the frame as its function is to prevent the center stand from rattling against the under side of the bike. Possibly goes somewhere on the swinger.
 
I would love to get another one of these!
Have you thought of a GSXR/750 Katana engine?
I have ideas now for my 1127 project. Maybe need some 550 Katana bodywork.
Tnx
G
 
gmansyz said:
I would love to get another one of these!
Have you thought of a GSXR/750 Katana engine?
I have ideas now for my 1127 project. Maybe need some 550 Katana bodywork.
Tnx
G
Click to expand...

I'm more of a Graveyard Cars kinda guy... meaning I like the idea of restoring back to stock... it's former glory!!! ;)
 
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