First ever bike rehab attempt: 1980 GS550

[bsullivan]

Hey,

A friend recommended I start posting here for help on a new project. I recently bought a 1980 GS550--though it might be a GS500. You guys tell me:

Anyhow--so I've got this bike and it doesn't work. I have never set a wrench to a bike before but I'm eager to learn. Have always wanted to do something like this. I'm hoping you all can help me along the way and I will post updates and whatnot.

First things. What I believe to be the crankcase cover (please forgive my present and ongoing ignorance) has a serious crack. It's only on the outside piece that appears to be replaceable--yay or nay?:

Beyond that, I think first steps are to clean the hell out of everything. Anyone recommend anything in particular for the chrome/engine block? Yes, it's true, I don't even know how to properly clean a corroded old bike. Next is a new battery. I really don't know what state it's in (I'm told it has compression), but I'd like to get it running and than maybe convert to a cafe racer.

Anyhow, any advice/thoughts would be very much appreciated on this, my opening post on the GS Forums.

Thanks folks.

Brian

 

[tkent02]

It's a 550L, it is perfect for the cafe conversion. I am parting one out just like it, should have that cover and anything else you may need. Get a list together and send a PM.
Should be a nice bike again one day, and all the information you could possibly ever need is in Cliff's welcome which you will see here soon. Welcome to the madhouse that is the GSR.

 

[cody3935]

crack?break lol best of luck ill help how i can. if you want to cleanthe engine oven cleaner+old tooth brush=success but if you dont get all the cleaner off it will turn white and look how it looks now so i would follow the scrubbin with a can of carb cleaner then spray it off with compressed air if you have an air compressor

 

[Nessism]

Oven cleaner is super harsh. I wouldn't ever use that stuff on my bike. Simple Green or some Gunk spray degreaser works fine.

As far as that broken cover is concern, I suggest you remove it and look to see if the crankcase is cracked too.

Good luck with your project

BTW, please check this thread to see some common issues people not familiar with wrenching on a GS may experience... http://www.thegsresources.com/_forum/showthread.php?t=171846

 

[bsullivan]

Thanks, gents. I will be posting again and PM'ing part needs soon. I have no idea what I'm looking at, so this is gonna be messy...but tons of fun, I hope.

 

[bsullivan]

What kind of battery does this thing take? Research tells me YB10L-A2. In the bike now is a 12A-A. Which is correct? Also, according to Autozone, the battery will cost $50. I know that's absurd--where else should I check?

 

[cowboyup3371]

Walmart, Batteries Plus, your local bike shop (where I get mine)

 

[bsullivan]

Also, where can I fine this welcome from Cliff that was mentioned?

The thread for newbie GS wrenchers is very helpful for process. Thanks!

 

[cowboyup3371]

He'll come along later but for now his site is: http://members.dslextreme.com/users/bikecliff/

 

[mike_of_bbg]

Heh. Looks like somebody thought the stock L bars weren't high enough already

That's your ignition cover that is broken. The cover and gasket are to keep moisture out more than to keep anything in - it's nothing that in and of itself would stop the bike from running.

$35-40 seems about the going rate for a plain 'ol battery in a store. Can't comment on the size as mine never had the battery box under my ownership and came fitted with a 14 size batt. However, if you're planning to keep the bike for more than a year or two you might just consider an AGM type battery. They're more expensive but are maintenance-free and have a reputation for longer lives. Seen starting at $55 or so online: more in stores as you would expect.

 

[BassCliff]

Hi Mr. bsullivan,

Sorry I'm late to the party. This isn't one of the sections I frequent so I've missed your first few posts. Normally an introductory post in the "GS Owners" section will get a "mega-welcome" form me right away.

Anyway, let me dump a TON if information on you and share some GS lovin'.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Rebuild Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. Now let me roll out the welcome mat for you...

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

 

[bsullivan]

Cliff,

You are a gentleman and a scholar. Thank you for the mega welcome and all of the tips/information that comes with it. As a wrenching newbie, this site and its members will be of the utmost importance to me. I will keep this thread updated with pictures and the like as my work on the bike slowly progresses.

Thank you!

Brian

 

[loud et]

Thanks, gents. I will be posting again and PM'ing part needs soon. I have no idea what I'm looking at, so this is gonna be messy...but tons of fun, I hope.

yes, tons of fun.... until you take off one part to reveal a worn out this, or a broken that..... and simple green and scrubbing.... and gunk engine degreaser and tryin to "make " a special tool to clean a certain crevice. and 20 more dollars for more purple power cleaner and more PB Blaster. Then you start to get a "vision " of what you are tryin to do with the bike, and then THIS certain part is not good enough, and THAT part is the one I must have....and holy crap, i have been polishing and painting parts for six hours and that was just one wheel and a few other lil things. then you start painting bolts, cause they are rusty and look like ****, but ya gotta getem shiny with a wire wheel first... then primer,,,, then paint.... then you obsess that the paint will crack on em when you torque em down, so you better bake the paint...... ha ha ha ha (BUT I WOULD NOT HAVE IT ANY OTHER WAY!!!) I am enjoying my rebuild quite a bit, and as I near having fully stripped, painted and polished rolling chassis again, I am a step closer to realizing I am making a bike that is all mine and I dreamed up. It is not a super perfect rebuild, but I am getting some pretty good results. Pretty cool. Cant wait to ride it already..... good luck, best wishes.. Its a beautiful obsession.....

 

[bsullivan]

So I finally had two hours to set up my garage and start poking around the bike. Next weekend will probably see the carb cleaning (gonna order new o-rings from the recommended source here). Two issues. New petcock required?

And I haven't tried rinsing this sucker out yet, but from the looks of it, this tank is going to need a thorough cleaning, for which I will need lessons:

 

[bsullivan]

Also, one of my rubber front tank mounts is missing.

 

[Redneck]

yes, tons of fun.... until you take off one part to reveal a worn out this, or a broken that..... and simple green and scrubbing.... and gunk engine degreaser and tryin to "make " a special tool to clean a certain crevice. and 20 more dollars for more purple power cleaner and more PB Blaster. Then you start to get a "vision " of what you are tryin to do with the bike, and then THIS certain part is not good enough, and THAT part is the one I must have....and holy crap, i have been polishing and painting parts for six hours and that was just one wheel and a few other lil things. then you start painting bolts, cause they are rusty and look like ****, but ya gotta getem shiny with a wire wheel first... then primer,,,, then paint.... then you obsess that the paint will crack on em when you torque em down, so you better bake the paint...... ha ha ha ha (BUT I WOULD NOT HAVE IT ANY OTHER WAY!!!) I am enjoying my rebuild quite a bit, and as I near having fully stripped, painted and polished rolling chassis again, I am a step closer to realizing I am making a bike that is all mine and I dreamed up. It is not a super perfect rebuild, but I am getting some pretty good results. Pretty cool. Cant wait to ride it already..... good luck, best wishes.. Its a beautiful obsession.....

Aint that the truth brother.

As far as your tank goes. I have done the vinegar method on an old worn out tank. Lets just say wow it really works. Then let me empahsize that as soon as you dump out the vinegear get some kind of protective coating in side or it will flash rust within the hour. My recommendation is if you plan on putting in a liner then have the Por 15 kit standing by if not I have heard someone sprayed the inside of the tank with WD-40 ...though I can't say for sure. Good luck and have fun.

Paul

 

[bsullivan]

Interesting...and cheap. Can you expand on the vinegar method or link to some place that can?

I'd never heard of POR 15 until 5 minutes ago when another friend suggested it. I have no idea what it is, but I'm going to look into it.

Thanks!

 

[bsullivan]

Replacement petcocks look like mine--they don't have a switch. Am I missing something? How can you possible turn the valve without a switch? Supposed to use a key or a screwdriver or something?

 

[Redneck]

Interesting...and cheap. Can you expand on the vinegar method or link to some place that can?

I'd never heard of POR 15 until 5 minutes ago when another friend suggested it. I have no idea what it is, but I'm going to look into it.

Thanks!

It is as simple as it sounds. White or apple cider vinegar does not matter which ever one comes in the gallon jugs ... Block off the petcock hole and fuel sender hole so it is whater tight. Fill 1/2 way with vinegar and half a bag of aquarium rocks. Put a plug or seal on the fill hole. Your gas cap will not work because they are vented. Then Shake vigourously. Set it down and forget about it. Every time you walk by it give it a good shake then about 24 hours later turn it over to get the other side of the tank. 24 hours after that drain out all the old vinegar and fill it half way with fresh vinegar. (you can reuse the aquarium rocks) and Repeat. You may need to do this cycle once more but that should take care of your rust problem. Remember the last time you drain it then spray the inside with WD-40 or re install your petcock and fuel sender and fill with gas, if you refill with gas make sure you go ahead and fill it up to make sure the petroleum can be absorbed by all the metal to prevent flash rust. Good luck.

Paul

 

[bsullivan]

Great, thanks! Will report back.