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Mike R's GS550/650 bare bones street racer

Already wound the motor, set the tensioner and used the kickstarter to cycle the motor a couple times and rechecked timing after all that. Everything checks out. No starter button either, running kicker only.
 
Ordered this after going through the reg/rec list for $58 shipped. I decided on this one for its sheer size. Should dissipate heat better than any of the other reg/rec's.

FH-0011AA FET 50 Amps / 100V rating 14.3V - 15.1V which seems to be one of the highest rated. I have plenty of room to mount it either under my tank or seat.

regulator.jpg


regulator2.jpg


All thats left for my electrical system is a battery, stator, and the wideband before I wire the bike up.

I also got a free H4 conversion from my friends dad. Fit like a glove in my headlight bucket and the beam patterns seem like they should work well. I want not only the engine but all the electrical on this bike to be high ouput and flawless.

The knee pain is going away as is the swelling. I'm hoping by next weekend I'll be more able to work on the bike. This weekend was pretty brutal as far as being immoble and in pain.
 
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boontonmike said:
Already wound the motor, set the tensioner and used the kickstarter to cycle the motor a couple times and rechecked timing after all that. Everything checks out. No starter button either, running kicker only.
Click to expand...

Sounds like you've got it all sorted Mike. Good luck with the rest of it. I will be following the thread closely.
 
Suzuki_Don said:
Sounds like you've got it all sorted Mike. Good luck with the rest of it. I will be following the thread closely.
Click to expand...

Thanks alot, good luck on your bike too. From what I recall reading you had a fire misshap and had to do a bunch of work to your bike. Are you still running the 700 piston setup?
 
boontonmike said:
Thanks alot, good luck on your bike too. From what I recall reading you had a fire misshap and had to do a bunch of work to your bike. Are you still running the 700 piston setup?
Click to expand...

No Mike my bike never caught alight. Just the way I worded the thread after I had started it for the first time after the rebuild. "It's Alight" - meaning all cylinders firing and running as planned.

The 700 cc piston setup is just the largest o/s piston available for the 650. It's 1mm o/s which takes the motor out to 699cc to be precise - nothing fancy.

I am currently in the process of changing the rear sprocket and while I am waiting for sprocket bolts to come from Japan I am in the process of fitting the 650 advance/retard mech. unit in place of the 550 unit on the end of the crank. The issue is the 650 unit is longer than the 550 one and the cover will not go back on in its original place without fouling the end of the advance/retard unit. I have to shorten things up a bit.
 
Suzuki_Don said:
No Mike my bike never caught alight. Just the way I worded the thread after I had started it for the first time after the rebuild. "It's Alight" - meaning all cylinders firing and running as planned.

The 700 cc piston setup is just the largest o/s piston available for the 650. It's 1mm o/s which takes the motor out to 699cc to be precise - nothing fancy.

I am currently in the process of changing the rear sprocket and while I am waiting for sprocket bolts to come from Japan I am in the process of fitting the 650 advance/retard mech. unit in place of the 550 unit on the end of the crank. The issue is the 650 unit is longer than the 550 one and the cover will not go back on in its original place without fouling the end of the advance/retard unit. I have to shorten things up a bit.
Click to expand...

Well that's good news that the bike didn't actually light up. I'll keep in mind the 699cc upgrade. How is the piston shape compared to the 650? Also, where do you aquire stock 700cc pistons? I may have a complete Dyna III setup for this engine when I'm finished including the whole crank triggers with mechanical advance unit.
 
I just spent 112 shipped on a NOS 550 stator. A little more than I wanted to spend , but with a bulletproof reg/rec backing it up it should work great and last forever. I have faith in Suzuki over the couple aftermarkets I can find out there.
 
I'm considering going to kick start only so I may have some questions for you.

Bruce.
 
boontonmike said:
I'll keep in mind the 699cc upgrade. How is the piston shape compared to the 650? Also, where do you aquire stock 700cc pistons? .
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I believe he is using the largest available oversize GS 650 pistons, which gives 699cc displacement, not GS 700 pistons. Their shape is totally different, as the 700 has four valves per cylinder.
 
tkent02 said:
I believe he is using the largest available oversize GS 650 pistons, which gives 699cc displacement, not GS 700 pistons. Their shape is totally different, as the 700 has four valves per cylinder.
Click to expand...

Noticed this when browsing the web. Also didn't have much luck finding NOS oversize pistons. Sounds very very interesting tho, as enough is never enough for me.
 
I'm in talks with someone about buying a complete 78 550 kicker for a pretty good price. My goal is to sell it off and make my money back but keep the engine. OnceI'm done with the current build I'd like to build a second engine 550/673, but now you guys have me thinking 699 , with even more power mods, i.e. valve jobs, head work, cams, and some more custom stuff that i dream of doing.
 
I'm throwing one together soon, 675cc, all stock, then taking my time to build a better one, 699, cams, head work, etc.
Got two spare 550 engines to work with...
Should be fun.
 
tkent02 said:
I'm throwing one together soon, 675cc, all stock, then taking my time to build a better one, 699, cams, head work, etc.
Got two spare 550 engines to work with...
Should be fun.
Click to expand...

Awsome ! sounds like we are on the same page. Keep me updated on that as I would love to follow that engine build. I'm thinking We should be able to squeeze 90HP out of these puppies naturally aspirated which is downright amazing.
 
boontonmike said:
Awsome ! sounds like we are on the same page. Keep me updated on that as I would love to follow that engine build. I'm thinking We should be able to squeeze 90HP out of these puppies naturally aspirated which is downright amazing.
Click to expand...

That would be amazing, and amazingly expensive I bet. I would be happy to get the performance of an old 850 without all of the weight and massiveness.
At any rate, it will be fun to make it happen.
 
Well, I picked up another 550, which I just posted to part out in the for sale section. this gives me the oppurtunity to have a spare engine for parts and a future high output N/A or turbo motor.

My knee is healing pretty good and I'm back on my feet walking. Slightly achey and painful, but I can start cracking on the bike again. I'm going to head up to the bike in a bit and work on finishing off my seat/seat pan. I ended up doing a little trimming on the seat so it wasnt so bulky yet still retains the same style.

I pulled the flywheel (which was tough as hell and bent my puller) and gutted all the starter clutch parts and the gear. That takes off a large amount of uneeded rotating mass on the crank. I'm hoping with the flatslide style carbs, quarter turn throttle, and all the weight off the crank that it'll have a dirtbike like snappy-ness to it. Only time will tell and I really need to start fiddlig with wiring the bike up and getting it prepped for start up. I've set a May timeframe for initial startup.
 
Decided to slap on the rest of my side cover gaskets, carbs boot o rings, bolt everything down. Threw on the ignition and fired her up. The carbs were overflowing from what I believe to be the float bowl settings. She ran on a mix of ether and gas after only a couple kicks. Scared the crap out of me. Video will be up shortly.
 


^^^^ Click for Video ^^^^

Still lots of work ahead, but a great motivational kick in the ass to know that it's a runner after all the mods.
 
Its a shouty one! Congrats on start up, now just a bit more fine tuning and you can get it to stay running for a bit longer. If you haven't already :rolleyes:

Cant wait to see this thing finished up and on the road, it's a kick ass build.
 
Pictures of the delted starter clutch assembly. Looks nice and light. In the future I would like to get a crank machined to tuck the flywheel in closer.

2012-03-12223332.jpg


2012-03-12223339.jpg


Hydraulic clutch:

2012-03-12221728.jpg


Exhaust hanger made from old shock linkage piece:

2012-03-18163120.jpg


Tore the carbs I bought off ebay down to do some mods, they were darn clean. I set the flaot heights and added some dyna needles I had from another set of carbs that are the same. They are on the 3rd clip from the top, pilot screws are 2 1/2 turns out and running 110 and 112.5 mains. Runs pretty damn good for a first go guess at setup:

2012-03-21185302.jpg
 
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