1982 GS 550 M rolling resto/customization

[gabos666]

Hi all!

I managed to buy my first bike, and I happy to find this forum aswell I bouth this baby for a bargain price, sadly it is in a vary sad condition right now. In Hungary these are rare bikes, it's hard to find parts, but I felt in love with the GS's classic look, and I wanted a project bike, so I could not leave it to destroy by the no money barbarian "fixes". Sadly she's got a hard time under the previous owner's.

Some picture from 2012 january from the moment of buy:

 

[gabos666]

TO-DO list

TO-DO list

My dream is to bring her back from the ashes, where the previous owners left them. I'm very angry, because they spent no money, just use it, so there are plenty things to do.
The goal of the project is to make the bike a reliable, classic looking bike, with some upgrades in the electrical system, suspension, and brakes. I have got no garage, nor tools right now. So I have to do it in the street, and sometimes in the company's yard, where I work. It's my first project, more or less for learn and for fun. The budget is low, so don't expect fast progress.

OK,so fault list first round:

-smoke from the exhaust system
-scooter mirror in the left side
-scooter turn signals all around (what a barbarian work! drilling's are awful, and looks very nasty)
- turn signal relay from an east german MZ, the signal rating is way off because the smaller turn signals
-electrical mess around the battery compartment, again barbarian hordes attacking
-dents either side of the tank
-rust and mess everywhere, they never clean it
-trash tires
-trash painting I think it was some 5 minutes ratle can painting
-right hand bar control switch is shot, they cut off the emergency stop button
-left hand side bar control switch, the high beam button runs hard
-engine side covers emblems are gone, and looks very sad
-not OEM exhaust system it is very loud, and doesn't sounds good, the police will catch me for it
-tacho cable is missing
-beveled drill for the licence plate (I know Conan again)
-DIY ugly seat cover

Huhh for the moment, that's all. That's enoguh for round one? I think so.

 

[gabos666]

Round one

Round one

I bouth it in january, i bring her for a very good mechanic to fix the engine smoke, and to change the tires. Right now, i still waiting to get the bike back. Very slow progress from the guy, but I know the engine will be flawless, and that's the point. I want to do the rest myself, so I'm glad to find the forum, andBikeCliff's Website is absolutely superb.

The smoke comes from the cylinder oil rings, and because the wear of the plunger simmerings.
Nothing horror there, just 30 year's war against the elements. Huh, I'm very happy about that. New gaskets, valve clearances will be set, new spark plugs, fresh oil, carburetor setup.

I will keep you guys informed from the progress.

 

[DannyMotor]

Youre not keeping that exhaust are you?? Hahah. Sounds like youre well under way!

 

[gabos666]

Youre not keeping that exhaust are you?? Hahah. Sounds like youre well under way!

For now, I keeping it, because the money. I bouth the bike for about 690 USD, and a good 4-2 exhaust system is way above my budget these times. I will put some sound deadening for temporary fix, because the police will hurt me badly for the loudness. And it sounds like trash, just roaring louder as the rpm goes up, you can't tell from the sound wich rpm zone are you. So it have to go, but not now It's impossible to hunt down a used OEM exhaust system here. From ebay the shipping cost will be high, so I have to wait, and put some money into it. There are many problems what I want to fix prior than that.

The light is too far now, but I just began the project, so I'am hopeful.

 

[Mista M]

welcome, sounds like a nice project. You may want to also check out http://forum.oldskoolsuzuki.info/cgi-bin/Yabb/YaBB.pl?catselect=discussions in the for sale section. They would be much closer to you than for shipping. Bike doesn't look too bad from the pictures. Hope you have it worked out soon.

 

[Nessism]

Good luck with your project! The GS gods will smile on you for taking on this project to bring the bike back from the dark side.

You might be able to make some new baffles for those mufflers. Better than getting busted by the cops.

 

[gabos666]

Messing around

Messing around

Sorry guys, but nothing interesting from the bike itself. The machanic still didn't put together the engine

But, I managed to buy some interesting things:

-Clymer manual
-rigtht hand side bar control switch (not exactly the same, but close enough to the original one, and much better looking)
-Kawasaki ZX10R regulator/rectifier for really cheap money!
-OEM tacho cable

 

[gabos666]

GS 550M with bigger kat head

GS 550M with bigger kat head

Just found this 550M in Hungary's biggest used cars site:

http://www.hasznaltauto.hu/motor/suzuki/suzuki_gs_550_m-5709099

Hehe! It's got the biggest katana's head!! Nice!!! I think i have to buy one myself, too.

 

[gabos666]

NEWS!

Finally she is came back!! And she is alive!

I am very happy right now!! Strong engie, good suspension, very fun to ride this 30 year old bike!!!

Bad side:
-I almost forget the nasty mad max look
-smoke!! I wrote it in the engine topic, maybe just some time needed for the new rings to broke in...
-today it refused to start, battery was empty


So first thing: electrical playground

I put the battery to charge, meanwhile I try to identify the cables who play with who, and where everything goes. I am pritty happy, more or less I could find out the basic layout. I used the Clymers manual as a reference, but there was some difference, because the PO's hecking.

Some picture from the present days, WARNING lot of image!!!

 

[gabos666]

 

[gabos666]

I was shocked, because the bike refused to start yesterday morning. I borrowed a battery charger, and charged the battery about 5 hours. Today morning there was no problem. Run like a charm.
I was concerned about the battery, and the charging system so I opened the Clymer manual, and do some test.

1./ battery didn't go under 10V under starting, so the battery is enough for a short period, 10,8V under cranking
2./BUT there was no charge!!! 12,8V without load on battery, and 12,5V with ignition on, and 12,2 with high beam, didn't go higher as i pull the throtthle

OK no panic!!! Alternator test without load... about 80V AC as should be....oh thanks god, the problem is not the alternator!!!

Let's check the connection between the reg/rec unit, and the alternator.

Some cleaning, and thanks to god, there was some light in the darkness!!

But, the reading was not sufficient enough: 13,6 V at 5000 rpm.

I think the connection is faulty between the reg/rec and the alternator, I have to double check the battery, and I suspicious about the reg/rec unit is faulty too.

So the time has come, when the MOSFET Shindengen FH-010BA unit after a long waiting, can do it's job once again

So my plan is the following:

-new reg/rec unit with direct connection to the battery, without the hassle with the handlebar control
-new fuse box with newer type fuses
-new connectors, and I think I will completely rebuild the wiring harness with fresh cables

 

[gabos666]

OK, there is a change in the story. This is not going to be a rolling restoration anymore. At least, that is the plan. I was so stupid to think, I can do this bit by bit. A can see now, every bit need some check and love. There is just one way to do this. I have to dismantle completely the whole bike. Do once, do it right.

I have no garage or a normal place, where I can work during the winter. I pull the carbs out, because the overheating, but they just have to wait. The baby kat may need to do the trip whit her own legs to the garage. So first thing is to find a garage. Hard project in Budapest (capital of Hungary). Fingers crossed, wish me luck.

A new project order:

-find a garage(near my rental,low cost,with electricity, I can only dream about a heated place, at least not in my budget category)

1./Complete tear down
2./make ready the frame to powder coating
3./repaint and polish the rims
4./new footpegs to rear and front
5./exhaust need new, or used OEM
6./rewiring the harness with improwed parts
7./side panel fabrication
8./replace the HONDA tail light, with a SUZUKI one
9./ new seat cover
10./ remove the dent from the tank
11./painting
etc. etc.

Some picture finally from the carbs:

 

[GateKeeper]

did you not get your welcome package ? if yes sorry, if no here it is, you can get lots of manuals and such from the site, and lots of tips and tricks , trouble shooting and so on...

Greetings and Salutations,

I have not been able to be on the forum much lately and many new members have not received their "mega-welcome". If you are here you probably have a 30 year old motorcycle that needs about 20 years worth of maintenance. You'll find all kinds of helpful tips, procedures, manuals, etc, in the links below. Let's get started.

Let me dump a TON of 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 Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. This is what NOT to do: Top 10 Newbie Mistakes. 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

 

[gabos666]

Thank you!

I am allready read these when I found this superb forum! This site is top, I have never seen better! I am sure, I can find here answers for my questions.

 

[gabos666]

spark plug question

spark plug question

OK, after I removed the carbs, I checked out the spark plugs.

They where really interesting( and frustrating too).

Guys, please help me, I don't understand why my 1&2 plugs are very different then my 3&4.

Spark plug no.1

Spark plug no.2

Spark plug no.3

Spark plug no.4

More concern is the 3&4. Much much crud and oil.
1&2 is more better, but there are problems too.

Help me please. There is something wrong in the head in 3&4, and something wrong in the air system or in the carbs/ exhaust at 1&2???

I think I have to check the top end myself. I never ever bring my bike to a mechanic!!! If I have a garage.....

 

[spyug]

Ok 1 &2 are, as you say, not too bad. I wouldn't worry about them. 3 &4 are definitely running richer (carbs) and show signs of a little oil buildup (leaking valve stem bushing or seals). However, not yet bad enough to panic over.

From what I'm reading, I think you should proceed to getting the bike starting and running right before you tear it all apart. I would definitely clean and rebuild the carbs with fresh o-rings and also replace the fuse block and R/r (as you mention) and spend some time cleaning up your connectors in the wiring harness and to all the electrical components.

Once it is running and charging well again then you can dive into the engine. it doesn't look bad enough to go crazy over right now.

Good luck with it.

Spyug

 

[gabos666]

Payday...

Soon I will put my order at cycleorings.com for the o-rings. Finally I managed to separate my carbs, but it was a nightmare job!!! Somebody worked in here, but long-long ago. All screws were shot. My pilot screw caps were drilled out sometimes, and the screws were nearly fully out screwed. I need some new jets to solve this problem. I shot some picture, but my data cable is at my friend, so update will come tomorrow with pictures.

 

[Chuck78]

It's great to see/hear your enthusiasm! Reminds me a lot of how enthusiastic I get about our bikes and other hobby projects of mine!

I'd been wanting a motorcycle for 11 or 12 years now, since two close friends of mine and I walked past a really awesome looking mid 1970's Honda CB750 with a sign "For Sale $1200." We all dreamed about it but never followed through until many years later! Same thing happened 7 years ago with a $1000 early 70's Royal Enfield 750cc Interceptor... Finally after meeting my future wife with a basket case 77 GS550B 3 years ago, I have recently acquired a 1977 GS750B project! I can relate to your enthusiasm, as I always get the same level of excitement and inspiration about hobby projects!

I've been begging Reda to let me pull the bike up our front stairs and park it on the enclosed front porch/mud room over the winter so I can work on it here! The answer is always "get the d#@$ house remodel done first, one thing at a time!"

Anyways, I wanted to congratulate you on your purchase, wish you the best of luck, and give you a little advice!
I wanted to suggest keeping the exhaust you have and just adapting some universal mufflers onto it. On Reda's GS550, I chopped off the original rusted up mufflers and welded on a stub of maybe 1-3/4" exhaust pipe to the Y-collectors on each side in order to clamp on an EMGO Dunstall style muffler to each one. I had to chop the mounting brackets and weld them back together in an "L" shape, and then mock up the mufflers with the stubs clamped in to get the proper installed angle to weld the stub onto the factory Y-pipes, but it was well worth if for a little over $100 US plus my time and welding.

The chrome is not the strongest and the metal is not the thickest (I figure regular chrome polish will keep them looking great for some time), but wow, those mufflers sound AWESOME! you can custom tune the softness or aggressiveness of the sound because you can remove the baffle and add or remove the fiberglass packing. They are fairly loud but sound AWESOME. Especially with the gnarly camshaft grind on the GS550's. you can add 'glass lining and even create an internal baffle like I did on my homemade glasspack to force more gasses into the outer muffler chamber and back through before being dampened by the fiberglass or steel wool.

EMGO makes many mufflers, and I hear the Dunstall style reverse cone mufflers are quieter, but no removeable baffles or cores like the others.

There are also many other companies where you could just order universal mufflers from. Good to know a friend with a MIG welder to help with brackets and mounts.

Best of luck, and don't forget to really really inspect your intake boots for cracks, and order the intake boot O-rings from Bike Bandit or somewhere , they do not come in the carb o-ring kit. and go up at least one or two sizes in main jets if you add a free flowing muffler and K&N intake filter or other more free flowing filter! you will run lean at higher rpm's if not, and you will seriously boost your engine's power if you do upsize these at least two sizes.

The GS550 honestly I believe is the best vintage japaneseengine in the 550cc range. Reda's is VERY FAST after we upgraded the ignition and coils to Dyna-S, put on K&N pod filters (harder to tune than K&N airbox type filter), and put on those EMGO Dunstall glasspacks... And it sounds REALLY AWESOME, I wish my 750 had the aggressive tone of hers! the 750 produces a deeper tone, but maybe my 4-into-1 mellows out the sound a bit.

Also, getting a buffing wheel attached to a hand held electric grinder and some good aluminum polish like Mothers will take you about 1-3 hours to put a mirror like polish on the shiny parts of the engine - clutch cover (w/oil filler cap), ignition cover, cam end covers, stator cover, and chain/clutch linkage cover... Makes them look REALLY SHARP! I think there is a factory clearcoat that you may find yourself buffing off, which I used fine steel wool or really fine sandpaper (more for scratches and severe oxidation) to help remove before polishing. The rest of the engine I believe was painted silver (or black) at the factory.

Good luck with everything, wishing you the best!

 

[gabos666]

Chuck!

Tanks you for these very kind words, and inspiration! I am in a very frustrating situation, because I have the will to work in my 550, but I have no garage, nor tools to do proper job. My primary goal is to find a place, where I can tear it apart, than I have to buy some tool to work with. Until than I began to renew my carbs. I will order the intake boot O rings, and all the necessary things to make them new again. Muffler question have to wait until the carbs done, I will use bigger jets to compensate the big opened mufflers. Factory airbox will stay. I have to find the cause of overheating. If a rejet solve the problem, than I can think of some mufflers. I am very much like the 4 to 2 system, so I will stay with it.

There is many possibilities in my mind about the little katana. I like to work on it. If I can find a garage, than this topic will blow out sky high