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Finally getting around to the 550/699 project....

No, it's bigger, it's heavier, and it lacks the six speed transmission.

And I don't have one.
 
Chuck78 said:
Also, look up Boontown_Mike's (I think that's the correct spelling etc) GS550 673cc racer project build, h e is using some 1991-ish GSXR600 flatslide slingshot carbs that are very light and very responsive. I picked up a similar set of BST33's. The intake boot configuration is a bit tricky, have to mix and match boots to get the correct offset but it worked for him.
Click to expand...

Boontonmike.....his ride is coo-oool.
 
So you ever get this going again tkent? I finished mine up and let me tell you, it's every bit worth the effort. So light and nimble, and now fast. I like it so much I may do another. Like a '79 or earlier. C'mon, "Get 'er done!"
 
Got going on it the other day, trying to get all the lights working. then I saw this on Craigalist:

20131108_134922.jpg


Thinking I'd take the pretty tank and such for my project, so I bought it today. Brought it home, rode it around a bit, now I need to rethink this thing. Everything works, just needs the routine stuff to be ready to rock and roll. I can ride it as a 550 for now, pop in the 675 or 740 or whatever engine when it is ready to go in, and ride it and take my time while the other project gets hammered out.
 
That's cool. I really want a spoked wheel model and I just really dig the 550 weight and 6 speed. And the 650 head really makes it run. Amazing the difference.

Looks like you have the CL syndrome as well. But for me, I don't have any funds so that at least keeps me from buying things.:rolleyes:

How many bikes now?
 
Sci85 said:
That's cool. I really want a spoked wheel model and I just really dig the 550 weight and 6 speed. And the 650 head really makes it run. Amazing the difference.

Looks like you have the CL syndrome as well. But for me, I don't have any funds so that at least keeps me from buying things.:rolleyes:

How many bikes now?
Click to expand...

I just counted, back up to nine, five of which are up and running. This one was cheap, for a running bike. He took about half of his asking price. Key, title, new battery and everything. :D

I'm considering using the 650 cylinder, bored for 750 pistons and the 550 head, which fits the 750 pistons shape better. Might even go with with bigger valves out of the 750. Got to pull all of the pieces out and do some pondering.

Maybe I should just go the 675cc with the 650 head for the first one. Just get er done. Then go hog wild on the second one.
 
Nine! Good grief. That's too many bikes for one person. I need to help you out by taking a couple off your hands :p

Maybe I should just go the 675cc with the 650 head for the first one. Just get er done. Then go hog wild on the second one.
Click to expand...

Agreed. Do the 675 swap first. It's easy and cheap and makes really good power for the little investment. It may suprise you how much quicker it is that you may not feel the need for the 750 setup, which btw, sounds like quite a bit more expensive for 75 additional cc's.
 
Which type bits work the best on aluminum???

Cutting the cases with a die grinder to fit the bigger 650 cylinders in, the stones clog up, the steel bits with the little cutting tips just wear out. What works the best?

20131205_103006.jpg
 
Rat tail file. :p
I took my cases to a machine shop to fit my 1150 cylinders.
 
A new carbide bit/burr, using a cutting wax helps prevent it from clogging. It's still going to happen to some extent.

cg
 
Thanks I got it done. Couldn't figure out why it didn't fit, actually had to take a lot of material off the webbing between the cylinders, fairly close to the crankshaft where it gets wider...

I'll get a pic or two.
 
Yeah, a lot more has to come off than what you think just looking at it.

So, what did you finally decide? Are you building out the entire bike or just the engine and putting it into the new 550 you bought?
 
For now, throwing the first 650 engine in the new one, it is really slow for a 550, not sure why. Think I will take the front 650 brakes off the other one, or maybe the twinpot brake conversion if it fits easily on the 650 forks. I think it does. That gives me a rider so I can take my time doing the original one.
 
Took a lot more grinding than I would have guessed.

20131206_155126.jpg


No way you could do it with the bottom end still together and not get particles everywhere.

20131206_155114.jpg


Also had to look underneath a dozen times to see where to cut next. Couldn't do that at all doing it with the engine intact..

But now it fits!

20131206_155247.jpg


The rest of the engine looks new inside, no wear on the dogs, shift forks, everything looks as new.

20131206_155206.jpg


Still have to measure the crank better but at first glance it looks great.

New stator, or maybe just near zero miles on an original. Not discolored at all.
 
Won't be long now. You gonna degree the cams right? They are timed very oddball from Suzuki for some reason. And yeah, my stock 550 was no road burner either tkent. The 650 and newly timed cams really awakened the bike, especially above 6-7K.

For jetting, I recommend getting the needles and mains from a set of the 650 carbs as your starting point. The needle is very different than the 550 needle and affects the jetting the most. I kept the 550 pilots but may swap those out come spring as it takes just a little to long to start when cold.
 
Sci85 said:
Won't be long now. You gonna degree the cams right? They are timed very oddball from Suzuki for some reason. And yeah, my stock 550 was no road burner either tkent. The 650 and newly timed cams really awakened the bike, especially above 6-7K.

For jetting, I recommend getting the needles and mains from a set of the 650 carbs as your starting point. The needle is very different than the 550 needle and affects the jetting the most. I kept the 550 pilots but may swap those out come spring as it takes just a little to long to start when cold.
Click to expand...

I haven't ridden a 550 in thirty years, but it seems slow. OK torque right off the bat, it gets going OK above 8,000 or so, but no mid range punch at all. My 650G was much much faster in the midrange. I think I need to go for a ride on the other one to compare. Have ony ridden it around the block since it has no lights, never really opened it up. I have been through everything else on the new 550, clean filter, decent compression, carburetion is close, no clutch slip or anything. Only thing I can think of is it could still have a clogged exhaust. I have a 4-1 I can throw on it for test ride purposes.

I am planning on rewelding a stock 650 header into a 4-2-1 try Y pipe, and using a Ducati muffler. I think that will have good torque, fairly light and should sound great. Also have a stock 650 exhaust I could use, but I don't want all that weight.

I am going to use the carbs from the 650, as my 550 carbs are VM, and they suck with the huge elevation changes around here. I think stock jetting should work for starters, if I can get the front half of the stock 650 airbox to fit. May use the filter half of the 550 box, may go with one big K&N filter on the back of the airbox, might just go with K&N pods. It all depends on what fits in the 550 frame.

Unfortunately that's it for now. I have to go to work. Someone has to deliver all of your Christmas presents, and as always there's the rubber dog **** to deliver...
 
I was looking at the cams today. Have both the 650 and the 550 cams to choose from. Which did you use and how did you set them? I know I need to use the 550 sprockets.
 
I used the 550 cams. However, if midrange is what you are after, the 650 cams are better. The 550 cams will put out more power up top. I ran 105/107 numbers. If using the 650 cams, I believe Suzuki Don ran 106/108.

I also am running the twin k&n filters. I don't think they flow as good as pods but better than the stock air box. And, I can pull the rack, change jets, and reinstall in just under an hour. K&N pods would be even easier which I have thought about switching over to. The space is tight in there and the twins just barely fit. In facts they touch the frame when installed.
 
Yeah, probably want the midrange more than the top end power. I can switch cams easily enough later. Try them both out. You are using 105/107, where were they set originally?

Yeah even with the VM carbs there's not much room, the K&Ns juat almost hit the frame.
 
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