GS550 Gearshifting Shaft Bent & more!

[mike_of_bbg]

These models all use the same part #. So basically any 8V 550 and a couple of 650s also.

1977 SUZUKI GS550B - GEAR SHIFTING
1978 SUZUKI GS550C - GEAR SHIFTING
1978 SUZUKI GS550EC - GEAR SHIFTING
1979 SUZUKI GS550EN - GEAR SHIFTING
1979 SUZUKI GS550LN - GEAR SHIFTING
1979 SUZUKI GS550N - GEAR SHIFTING
1980 SUZUKI GS550LT - GEAR SHIFTING
1980 SUZUKI GS550T & ET - GEAR SHIFTING
1981 SUZUKI GS550LX - GEAR SHIFTING
1981 SUZUKI GS550TX - GEAR SHIFTING
1981 SUZUKI GS650EX - GEAR SHIFTING
1982 SUZUKI GS550LZ - GEAR SHIFTING
1982 SUZUKI GS550MZ - GEAR SHIFTING
1982 SUZUKI GS650EZ - GEAR SHIFTING

BTW, if those wheel bearings are anything other than buttery smooth, plan to replace them as soon as possible.

 

[Suzuki_Don]

Glad it's all coming together for you. There's no reason it should not work OK when it is all reassembled.

 

[Joneman]

Getting there

Getting there

Mike, thanks for the valuable information! I am no expert on the bearings, and as they don't cost too too much I will buy them the next time I make an order/work on the bike.

Don, you mentioned how to torque the nut on the clutch. I guess for this to work the sprockets and chain would have to be installed? I had the bike in 6th but it was turning, so I got it torque'd on another way to 35 ft-lb.

Don: "Put the bike in 6th gear with the front sprocket and chain in place and lock the back brake on as hard as you can and torque the sprocket nut up to the required torque."

I put the clutch all back together... that dang oil pump drive gear gave me a go for a bit trying to get its dogs to mate with the clutch housing. Kind of hard to do when you can't see it and theres no room for fingers, but I think its good.

Trying to "torque" the spring bolts was interesting. The torque wrench I have only goes as low as 20 ft-lb, so I looked at the pictures I had taken before removing the basket and tightened by the same amount. Basically it was up to the point that I could no longer tighten then with a socket on a screw driver (less torque). I am hoping this will be around the required 5 ft-lb.

I sprayed the new gasket with some WD-40 and then installed that, putting some anti-seize on the cover bolts. I then added 2.5 litres of diesel oil up to the Full line (Rotella 15W-40, first time using diesel in the bike) and kept the same filter. I'm going to change the oil and filter within the next 200-500kms to get any debris out of the engine.

Everything seems to be fine now and I will get the new sprockets, chain, gear shifter lever, footpegs, kickstarter and a few last things installed with a clutch adjustment and then start er' up! They are calling for a great, 20 celcius + weekend, but I am going back home for Thanksgiving (Canadian)... they wouldn't understand if I stayed to work on the bike. I hope its not too cold next week for riding!

On a side note, the engine re-assembly pages in the suzuki service manual are garbage. There are many steps missing compared to the Clymer manual.

Thanks again guys for the help! Have a great weekend

 

[Joneman]

All Done and Working - Thank you!

All Done and Working - Thank you!

Hello Guys,

Thanks again for all the help. I have since taken the bike out for a spin or two and it works good! The shifting lever doesn't always fall back into position, so some of my gears are not catching right away. It might be just adjusting the pedal placement, or perhaps it is the bent shaft... I still haven't picked my "new" one up yet across the border. Any thoughts about this are appreciated.

One thing I screwed up was riveting the chain link pin. It wasn't flaring enough and then it flared too much. I was aiming for 0.015" larger than the original pin size at 0.204", so roughly 0.225 (with some extra). I ended up getting 0.244" so I will be keeping a close eye on this link for any cracks.

As you can see we got a surprise storm, with a lesson learned: use bungee cords to keep a cover on.

I plan to do a valve adjustment and complete carb cleaning over the winter. I am sure you will hear from me again

Merry Christmas and a Happy New Year!

 

[mike_of_bbg]

A couple of times I've had that issue it's been some corrosion between the shifter and the frame peg causing friction. A little emery cloth and some white lithium grease fixed it right up. I hope that's all it is for you. However, if your shaft is still bent that may well be the cause.

Regards and Happy Holidays.

The shifting lever doesn't always fall back into position, so some of my gears are not catching right away. It might be just adjusting the pedal placement, or perhaps it is the bent shaft... I still haven't picked my "new" one up yet across the border. Any thoughts about this are appreciated.