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'78 GS550E - Budget Cafe(ish)

  • Thread starter Thread starter MT.thumper
  • Start date Start date
M

MT.thumper

Guest
Picked up a '78 GS550E a couple of weeks ago for $200. PO said (of course) he had gotten into dirt biking a couple of years ago and just stopped riding it; it had just been sitting in his garage for the past two years. Of course, "It ran when I parked it". Didn't run (dead battery) when I looked at it, but seemed in good shape and like a good base for a budget cafe build. Originally was thinking of a quick clean up and flip. However, my other bikes ('76 XT500, '78 TT500, and '66 CB160) are all one seat cafe builds, and my son thinks I should have a two seater so he can ride with me.

So, things done to date:

  • Got it a new battery.
  • Was missing the left side frame cover; got that too.
  • Painted the tank (rattle can - might need to take it for a real paint job at some point since a drop of gas already did a number on it), frame covers, and duck bill.
  • Removed the rear tail light and recessed an LED light in the rear of the duckbill.
  • Clubman bars.
  • New, lower profile turn signals.
  • PO also sent me away with an unmounted belly pan (took a bit to figure out a hardware set up to mount it).
  • PO also had a Supertrapp exhaust he had never mounted because it didn't quite fit (hit the passenger peg on the left). Got a short section of exhaust pipe expanded and finishing up a bracket to hang it.
  • Pulled the 4 into 1 exhaust header and put in new exhaust gaskets.
  • New oil and oil filter.
  • Was thinking of K&N air filters, but seems like there is consensus on this site that the stock set up is fine and changing it makes jetting a PITA.
  • New plugs.
  • Seat was carved up by someone with a bread knife, left rough and recovered with the original vinyl. Reshaped it and waiting for upholsterer to get to it.
Unfortunately, have not yet been able to get the engine fired. Still working on that. I think it's the points (more investigation to follow). Attached picture is the start.
 
Mocking up exhaust to try and figure out preferred extension.
 
Clubman bars. Needed to get risers because they hit the air valves on top of the forks and wouldn't seat.
 
Tail/brake light is a trailer LED brake light. Got it at WalMart or the local farm and ranch supply. Was $13 or $18. Can't remember if I originally saw it on this board, but thankful to whomever had this idea and posted it.

Also a good view of the new turn signals.
 
Clubman bars didn't clear the schrader valves on the tops of the fork tubes, so had to get handlebar risers.
 
Couldn't help but buff the little covers and replace the crappy, phillips head screws with black, allen flat head bolts.
 
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