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First Street Bike Project - with a few questions

  • Thread starter Thread starter Guest
  • Start date Start date
Yeah, I have more work to do on the carbs. Not anywhere as shiny as Renobruce produces but I'm going to learn one way or another. I like shiny haha.

Going to get some sandpaper tomorrow and work some more on the disassembly. Thanks for all the encouragement. Will need it now that it's getting much colder here now.

I hope I can get the bike back to close to factory under $500. I think that will depend on if I have to pay someone to paint the tank, fender and side panels...
 
More disassembly...

More disassembly...

Nothing much exciting to post except more work on the tear down. So far, nothing looks too major. The wiring is a mess. I may just go with a new loom if I can still get one at a reasonable cost. I'm a little worried about the header bolts. A couple look really bad...anyway, making good progress given my other time commitments.

gs550m%252520029.JPG


Sci85
 
Thanks. I'm trying to take the advice I read somewhere on hear to try and do something no matter how minor each day. Tonight I was sitting in the bleachers watching my sons wrestling meet though. I didn't even get to look at it this evening haha.

Is it just me or does the top subframe rails appear higher on this M model than the same year L? I figured the frames would be the same but maybe not?

Sci85
 
Hey all I did was wire wheel the frame, then took some sandpaper to it, wiped it down, and next thing you know, I am about ready to paint the frame, and I didn't even feel like working on the bike tonight....

Funny how things work out sometime....
 
Nice work, I have mine in the kitchen and redoing some things on it as well. I keep motivated by it being in there and the wife having to work around it some LOL. Best of luck on the rebuild.
 
Sci85 said:
Is it just me or does the top subframe rails appear higher on this M model than the same year L? I figured the frames would be the same but maybe not?

Sci85
Click to expand...

M and L bikes have different frames. In fact all L bikes have different frames than their E, M, or G counterparts. The rear sub-frame is different to cater to the lower stepped seat fender that gives the L it's "custom" appearance.
 
I picked up my 82 gs550m about 2 months ago. I am jealous that you get to customize your bike more than I did, although I love it being in mostly original shape. I'm not a huge fan of the tiny signal lights that the po put on there, but I'm looking for something else to fit on there.

I have looked at bikebandit.com website for different things and have seen the gas tank emblem available. Here is the website:
http://www.bikebandit.com/1982-suzuki-gs550mz/o/m6087#sch267518
It seems like they are in stock still, but you could probably have someone make you the same thing for cheaper.

The compression on my bike is around 115-125 and it seems to run just fine, it has around 2100 miles or so. The choke lever is mounted on the left side handlebar just underneath the light switch and horn button. The choke on mine pulls very easily. I lubed the cable and all the choke related parts on the carburetors too, which helped a lot.

picture.php

302049_2551072020078_1352194177_32913618_1852582653_n.jpg
 
Yeah I saw that you scored a sweet one B-rent. I was sooo jealous when I found your thread. What a great find. Good to know that I have someone who I can go to for OEM questions now. I don't plan on any major mods. In fact, I really enjoy the stock colors and look so that's what I'm probably going to do. I did see a sweet looking one in black and yellow that was really nice though.

Enjoy her. She really is a beauty.

Maybe, when I get mine finally done (and get my license again hehe), we can meet up for a ride. I've never been to Utah and hear the scenery is gorgeous.

Sci85
 
TheCafeKid said:
As to the stickers, you have a fairly rare model there so I'm not entirely sure they'll have them, but a company out of Canada called reproduction decals has a pretty fair number of the decal kits for these and other old UJMs.
What's more, if they don't have the decals, and you can find a set of high resolution pictures of what they're supposed to look like, and send the company your bodywork when it's ready for them, they'll make a set for you for free since your stuff was a guinea pig. At least they used to.
Welcome to the GSR and enjoy!!
Click to expand...

Gotta say +1 here. I have used them in the past, most recently a decal set for the Seca Turbo. All high quality 3M vinyl graphics.

Looks like a cool project you have going, you found the best place on the web for GS knowledge.
 
It would be very fun to ride around with another 550 Katana. A long road trip would be great to do sometime. Just let me know if you need any sort of reference, and I can get you some pictures. It seems that most everything is stock on mine except for the Vance and Hines 4-1 and the signal lights, oh and the bar-end mirrors which I like more than the stock mirror placement.
 
Cool beans. And thanks! I'm sure I'll be hitting you up before to long.

After looking around, I think my decal is the same one used on the bigger bikes which seem to have plenty of availability of parts.

Sci85
 
Well, i got all the wiring out finally and the tail light and fender. It's been slow going lately as I am low on moto funds so I have to get this little CR80 project done and sold before I can acquire any major pieces for the Suzuki. Hope to get this one done in the next couple weeks and sold asap but there is still lots to clean up. Look at all that room to work in hehe. Love 2 strokes!

DSC03243.JPG


And here's a nice shot of why you should regrease your swingarm bearings regularly. These came out of the shock/swingarm linkage. Total rust and not a drop of grease. Yikes!

DSC03253.JPG

DSC03254.JPG


I gotta get this CR80 done! There was a running 1979 GS850 (no title) on Craigslist about 30m away from me that showed up today for only $225 bucks! All there except for the exhaust! Dang, I want to go snag it bad but outta funds :(

And here is where the baby kat stands...At least I now have the new oring kit, needles and seats and stainless bolts for the carbs. :)
DSC03255.JPG


Not sure what next disassembly step should come next. Front end, rear end, engine out or ? Taking suggestions...

Thanks,

Sci85
 
Hey Sci, that little CR looks like a whole heap of fun between two wheels, maybe when Jennifer is done, I will start looking for a dirt bike again, I do miss enduros, was a fun way to stay fit.
If you are pulling her apart, down to the frame, I would suggest leeaving the engine until last, then tipping it onto the right hand side, and lifting the bare frame off the engine, still a little fiddly, but a damn site better than trying to man handle the motor out yourself, ask me how I know....been there, done that, a few times, and have the bad and buggered back to prove it....not a good idea.
 
Hmm, how much do these motors weigh? Yeah, my plan is to go all the way down to the frame. Even though this is my first street rebuild, might as well go whole hog huh?

So I guess it doesn't really matter then but I figure it's probably easier to hold up the rear while taking off the front then vice versa so I'll probably go rear first.

Good idea with laying it over. I would have never thought of that and probably hurt myself trying to lift that motor out haha.

Sci85

PS. Yes, dirt bikes are a great way to stay fit. I race 'em in the summer and have more fun than you can imagine.
 
Last edited:
Sci85, I have to admit that this was/is, by far,the absolute EASIEST WAY that I have ever changed these engines by myself.
Effortless in fact! ;)

This was with my '82 GS1200G.
I forgot to take pic's on the removal but, the instal was just the opposite and just as EASY!
Just place a board under the engine to raise it flush with the frame rails after the mounts are all disconnected.
Place another jack or same height platform outside of the frame at the same height.
Then, I just walked the engine over by rocking it side by side until it was in the cradle and dropped it into place. :)


DSC04090.jpg


I just pushed the jack over to meet the frame.

DSC04089.jpg



DSC04093.jpg



Daniel
 
Daniel, you must have some good luck there, and I hope some of it rubs off on me when I go to put my engine back in....

I had a heck of a time, just getting it out, and I laid the frame and engine on it's side, as I didn't have 2 jacks, plus the air box gets in the way as well and has to be back in the bike prior to installing the engine, and it was a pain trying to get it out in the first place,,,,very little wiggle room...
 
Perhaps you can loosen all of the airbox mounts and use some tight bungee cords to gain a few millimeters of room as I did on this GSX1100G:

DSC06222.jpg


Daniel
 
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