My '82 GS550MZ Refit

[doug g]

Where in Philly r u? I am not far in Media Pa and have been playing with these bikes for a long time. Pull the carbs and get to it. any questions or if help is needed let me know. I have everything that is needed to get those carbs ready to go.
As far as tires go. They can be done by yourself you just need some tire irons. Did you order new tubes too? I would change them as they are so old. Cycle Gear in Springfield should have them in stock as should your local shop. if not they can order them for u. try and give your local shop the business if possible. lord knows they need it.

 

[detorn]

Just to be clear the valve clearance is the same as the tappet clearance? I've looked over the manual and this seems doable. The only issue I will have is I don't have a torque wrench to replace the top of the motor, but I should be able to borrow one.

My goal with this keeping track of everything with this thread is to be as complete as possible. Though there is a lot of good information on this site, a lot of it is fragmented, incomplete, and assumes prior knowledge. So even when I do find info in other threads, I will link back to it here and annotate it, so it is complete as possible.

I want to have as much information in this thread as possible, not just for me, but for the next guy who naively gets into this kind of project. Likewise, I want to keep a running total of the loot I spend so the next person like me who thinks he can get a $500 bike and ride for a summer, knows what they are actually going to spend by the time they get on the road, it's not about return on investment.

 

[detorn]

Where in Philly r u? I am not far in Media Pa and have been playing with these bikes for a long time. Pull the carbs and get to it. any questions or if help is needed let me know. I have everything that is needed to get those carbs ready to go.
As far as tires go. They can be done by yourself you just need some tire irons. Did you order new tubes too? I would change them as they are so old. Cycle Gear in Springfield should have them in stock as should your local shop. if not they can order them for u. try and give your local shop the business if possible. lord knows they need it.

This is awesome man, it is great to have someone so close. I have some tools, but not the calipers or dip for the carbs, and the torque wrench for the motor cover (was assuming I was going to have to buy it for one time use, it would be great if I didn't have to). PM me your email address and lets talk when you get some time.

 

[detorn]

jusr read BassCliff's mega-welcome all the way through instead of just looking it over... feel a little silly now about some of the questions I've asked.

 

[79FiveFifty]

.....and the torque wrench for the motor cover (was assuming I was going to have to buy it for one time use, it would be great if I didn't have to). PM me your email address and lets talk when you get some time.

You would be mistaken if you think buying a torque wrench and GS ownership are a one time deal :-\\\ lol

I have owned my bike what.. a couple weeks? Have already turned every nut and bolt outside of the engine on the entire bike. Replaced about 50 small parts, and make adjustments on a daily basis at this point, so investing in some tools will provide you with a lifetime of service!

 

[Charlie G]

DETORN,

I think you have found a sweet motorcycle and I wish you luck. I don't think that are that many of those 550m out there to be found.

By the way...

Big T Quote "1. Your bike has mechanical valve settings - you take off that cover on the top of the motor and check the clearance with a feeler guage and adjust the screw accordingly to spec" .

I think Big T is mistaken in stateing you have "Mechanical Valve settings". I'm pretty sure you have shims that need to be swapped around to bring valves to spec. Not that hard to do, once you have done it once or twice.

cg

 

[detorn]

DETORN,

I think you have found a sweet motorcycle and I wish you luck. I don't think that are that many of those 550m out there to be found.

I'm pretty sure you have shims that need to be swapped around to bring valves to spec. Not that hard to do, once you have done it once or twice.

cg

Thanks for the compliment. And you are correct about the shims. I read though my manual once it got brought up.

 

[detorn]

You would be mistaken if you think buying a torque wrench and GS ownership are a one time deal :-\\\ lol

I have owned my bike what.. a couple weeks? Have already turned every nut and bolt outside of the engine on the entire bike. Replaced about 50 small parts, and make adjustments on a daily basis at this point, so investing in some tools will provide you with a lifetime of service!

If you needed a computer fixed I have every tool you could need. I just have never wrenched on a car or bike before... This is serious, and I haven't mentioned it yet, but I've only had my drivers license for a month, my M permit maybe two weeks now. it is all very new to me.

The main point is, yes I will get all of these things, but can't get them all now or all at once. So it would be good to have some local support. specially someone who know these specific bikes. And the one time thing I just meant more the dip, than the wrench.

 

[doug g]

This is awesome man, it is great to have someone so close. I have some tools, but not the calipers or dip for the carbs, and the torque wrench for the motor cover (was assuming I was going to have to buy it for one time use, it would be great if I didn't have to). PM me your email address and lets talk when you get some time.

I check this page daily. just pm me. talk to ya soon

 

[detorn]

help finding a part.

help finding a part.

The carb rebuild series says to replace the Rubber pilot jet plug, but I can't seem to find it on the fiche.

it also says to replace the drain screw gasket, so i need to find that too.

Can someone help me find these and the intake boots?

And just to double check, is this what I want to buy when/if I replace the petcock? Am I correct in assuming that I'll need to but the o-ring too? Going to try to get through as much of this as possible over the next three weeks, so I'll need to order soon.

I'm assuming all the o-rings it says to replace are what I ordered from Robert Barr...

Anything else I need?

Thanks

 

[Big T]

DETORN,

Big T Quote "1. Your bike has mechanical valve settings - you take off that cover on the top of the motor and check the clearance with a feeler guage and adjust the screw accordingly to spec" .

I think Big T is mistaken in stateing you have "Mechanical Valve settings". I'm pretty sure you have shims that need to be swapped around to bring valves to spec. Not that hard to do, once you have done it once or twice.
cg

And here I thought he had a 16V motor!

Boy, I'm getting old

Dethorn,

Changing the shims isn't hard, hopefully you can borrow the tools.

Search for the Valve shim swap club and see Steve for his spreadsheet to keep track of your shims

 

[detorn]

The carb rebuild series says to replace the Rubber pilot jet plug, but I can't seem to find it on the fiche.

it also says to replace the drain screw gasket, so i need to find that too.

Can someone help me find these and the intake boots?

And just to double check, is this what I want to buy when/if I replace the petcock? Am I correct in assuming that I'll need to but the o-ring too? Going to try to get through as much of this as possible over the next three weeks, so I'll need to order soon.

I'm assuming all the o-rings it says to replace are what I ordered from Robert Barr...

Anything else I need?

Thanks

plugs are part 38 on the fiche, or part number 13357-44080 (be careful on bike bandit ordering this, it is mislabeled)

Part shark has the best price, but the shipping is so high I'm going to wait to order them.

drain screw gaskets are coming with the o-ring package (i shelled out the penny not knowing if I needed them or not. was a good move).

the intake boots I'm still waiting for someone to confirm, I think the part numbers are:
13881-47030
13882-47030

and that I need two of each?

rear tire arrived. front tire, turn signal lens, and brake light are in route.

 

[Larry D]

.........the intake boots I'm still waiting for someone to confirm, I think the part numbers are:
13881-47030
13882-47030

and that I need two of each?......

Depends on which boots you want.......the boots you list are for the airbox....there are also boots, under the cylinder head section, which are parts numbers 18 and 19. Or 13110-47010 and 13120-47010. You need two of each of these as well....left and right. You should have received part number 22, the o-rings, with your carb o-rings from R. Barr.

 

[rustybronco]

the intake boots I'm still waiting for someone to confirm...

and that I need two of each?

Why do you think you need them?
are they torn, cracked or hard, or do you just like to spend money?

pictures of them please...

 

[Steve]

... and see Steve for his spreadsheet to keep track of your shims

Here, I'll make it easy for you to find me.

See the last part of my sig for spreadsheet ordering info. :-\\\

.

 

[detorn]

Why do you think you need them?
are they torn, cracked or hard, or do you just like to spend money?

pictures of them please...

I would have rather not had to replace anything

But since I'm going to be in there and all... I'll take some photos once the carbs are off.

But the why is that I'm just going to work through the common problems part of the super greeting. This bike hasn't been serviced in 25 years, so the stuff that can go wrong probably will.

 

[detorn]

updates.

updates.

Put the new plugs in today and all four cylinders fired. So at least we know the engine does work. Here is a clear pic of the old plugs in order (one is to the left).

I can't tell if it is the gas tank leaking or just the overflow splashing. I hope I don't have to add seal tank to the list. I'll know more once I get the tank off.

short vid of it running and stalling out with the leak shown. (vid). It didn't stall right out when I rolled the throttle, so it must have been the bad plugs not firing and flooding it out.

I played with the intake boots a little and the covering on them just started falling off .

finally, after shut down it made a weird pop corn noise, any ides? (vid)

the o-ring package arrived today, so I may be able to get the carbs done this weekend. woohoo

 

[Big T]

Those plugs look thrashed -#3 may not be firing, which us what your vid kinda sounds like

That thing on the tank looks like rust through - let me guess, it sat for years on the side stand, condensing water into the low spot on the tank

Have you looked inside the tank? Rusty? Get one of those little inspection mirrors on a handle and check it out

 

[waterman]

The popcorn noise sounds from your second video is typical of a motorcycle cooling down after shutdown. Nothing to worry about, just metal contracting as it cools, all of my bikes make these sounds. The running condition of any bike is hard to tell from audio recordings, at least to my ears.

Before throwing gobs of money at the intake boots, remove carbs and check to see if the boots are ripped or cracked on the inside. The flaking you see is not always indicative that they are trashed. Personally, I would be most concerned about carb condition and after a thorough clean by soaking, put them back on and see how it runs. I had a torn intake boot that I temporarily repaired using high temp RTV :-$ just to make sure motor was sound. Then I replaced boot after finding that all four cylinders were firing. I didn't want to sink too much money into project before I found out if it was going to end well. In your case, I would give that tank a close inspection, hopefully it is rust free on the inside and that is a spot of exterior corrosion. If not, then getting it fixed could be rather involved and potentially expensive if you need to replace since this bike is kinda scarce to find parts for.

I wish to welcome you to the forum and I am not trying to scare you away from fixing this bike. I am sure that you cannot wait to hop on bike and take off, but unfortunately, this bike like almost all used bikes will need some maintenance first.

 

[detorn]

manual is not clear.

manual is not clear.

With school done I started the refit in ernest today. Some good news first. The tank doesn't appear to be leaking. The petcock vacuum (the smaller hose on the petcock, I think thats what it is) hose was off and split at the end. The petcock itself seems to be fine, though I have ordered the o-ring so I will probably install the new one.

I was originally going to get all oem replacement parts, but now I think upgrading a couple of things may be cheeper and better for the long term health of the bike. So, if you have recommendations for replacement hoses let me know.

The bad news. This thing is unreal to get apart. The clutch cable runs through the carb assembly.

Question: Is it okay to unhook the clutch cable from the trans side (pictured)?

Still haven't managed to get the carbs out, I will take another run at it saturday. The bike is apart not, so if I wasn't committed before I sure am now.

Seriously, the instructions in the manual for removing the carbs are "Remove the Carburetors."