• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

77 550 cafe project - couple questions.

  • Thread starter Thread starter DCrippa
  • Start date Start date
D

DCrippa

Guest
So it's been a long while since I picked up a bike that a previous owner had on here ... I've been slowly amassing everything and I'm still missing some parts to really bring it together.

One thing I'm having problems with is a lack of fasteners - is there a bolt kit one could buy for this bike - ie exhaust lugs etc? Or how does one go by identifying size pitch and thread when missing screws / bolts?

Sorry for the lack of pics (though there are some of it in it's former glory posted by the PO on here). I'll get around to adding some as I make progress. I still need to figure out a seat - battery location and electronics. Working with old parts (hope they work!), so she's not going to be a looker. Just want to get her running and then later maybe redo everything with new wiring / upgrade electrical system / timing.

Gonna have to stick to the true cafe spirit since I don't have much to throw at this project for a while.
 
Firstly, Jump on ebay. Jump on Z1. I bought a full bolt kit for my engine from z1 along with studs for the exhaust manifolds.....its sorted by bikes. Z1 is the way to go for bolt kits. then you just have to work out which screw goes where. Oh and it converts it to alen bolts so you cant strip the heads.
Remember to use a bit of loctite.

I'm building a cafe too...gs1100...good luck man.
 
Last edited:
Those Z1 screw kits are just for the engine covers. There is nothing for the headers.

You might want to visit your local hardware store. Metric fasteners are pretty common these days.
 
There are def bolts for the headers but you have to use the kawaski ones. They are the same pitch/width whatever the measurement is.
Do a search on my posts, I brought this topic up and it has the info it in. I just got mine in the mail today from z1 (yes im in australia!) and they fit lovley.

Peace.
 
Thanks a ton guys... I've finally finished all my other projects (home renovation, back yard deck etc...) and can now focus on this project... I'm in no rush since I have the trusty Fizzy to ride. I will be updating as I go along. I think I will take a shot at trying to find a match for the header bolts at HomeDepot...

Would the manual have the pitch and sizes listed of each bolt? I'll search for your thread as well.
 
DCrippa, you'll have better luck finding a better selection in the exact number for a good price if you go to Ace Hardware. Just saying.
 
Thanks Cowboy - I'll go to Ace instead - love the instant gratification of having a part immediately - I hate waiting around for parts in the mail.
 
So I got the carbs all mounted up with pods, bought a battery, fuel line, oil.... still need to figure out the electrical system but at least with a battery - once wired up I'll be able to see if she cranks. I still have a ton of work to do. Need to make a seat, I got the missing exhaust studs at Napa.

I'm really hoping the old electrical cables/wire harness and components work out - if not there'll be that to deal with, as well. It currently has clip ons - and while I like the look it's causing problems for me - hits the tank and is a problem trying to mount the light with the stock mount, will either have to put different bars on or push the clip ons out more and figure out a different mounting arm for the light.
 
Last edited:
Need some help

Need some help

Does anyone know the size of the bolts needed to mount the guages?

I'm not near my bike now and would like to pick these up today on the way home so I can mock up the gauges & light this weekend... Anyone know the size length and pitch off hand to mount the guages?
 
The manual lists various sizes used but not the specific size for that bolt...

Anyone care to take a guess 10, 12 larger?
 
No-one? Really?

I'll measure it with calipers tomorrow and will eventually get the right bolt... but I gotta say - I thought someone would at least chime in by now and help out - it's been quite a pain in the ass on the missing bolt tip - and the manual doesn't tell you info on all the bolts. Am I the only one with a bike that is missing a lot of bolts?
 
Just a tip I found here when sorcing bolts for mine. The factory part # IS the bolt size. Typically found on the various on-line parts shops that show the OEM microfische prints and then list the OEM part #. There is a choice in tread pitch but the smaller ones are corse thread and the larger bolts are fine...
For example, 01500-0865B is a 8 x 65 mm bolt.
 
Yep, if I can't find the pinch bolt I removed from front fork for the leading axel, part # 01500-08507... I'll be going to Fastenal and buying a 8 x 50 replacement.
Now about that thread pitch... I knew I saw it somewhere!

mriddle said:
Suzuki uses standard metric thread pitches up through 8mm:
3mm x .5
4mm x .7
5mm X .8
6mm X 1
8mm X 1.25

When you get to 10mm fasteners, Suzuki usually uses fine pitch threads:
10mm X 1.25
12mm X 1.25
Click to expand...
 
Last edited:
Thanks again. I know something like this probably is pretty obvious to you more seasoned guys - kinda like how a master mechanic can pick out the right socket in one take... instead of trying a couple or three like I sometimes do to find the right one that fits lol...

You're right - most of the bolts have been 1.25 pitch. Hope you find that one it's pretty important.
 
So I finally got around to sourcing the missing bolts... it may seem pretty obvious and easy to you guys but it was pretty frustrating and a real pain in the ass. Numerous trips to various hardware stores... lists with caliper readings and then figuring out the pitch.

I finally got around to hammering out the tank - didn't get to snap a pic but will update soon with some... put the knee dents in on it and flattened the welded seam - just need to remove the paint off it now. It's nice to make decisions and finally move forward... I've decided on a paint scheme - basically it'll be the stripped metal tank clear coated with the same lines that were on the stock tank - I got an airtech seat (ducati 750) will take quite a bit of modification to get that to work... so that's the next step aside from getting the bugger running. I'll have to find a gun metal gray paint to match the look of the exposed metal tank.

Due to clip ons - the stock headlight mounts don't work - so I've been trying to make some steel straps work - they've been really hard to bend - it's not quite at the circumference needed but I think if I wrap rubber or leather around the fork tube to make up the difference I'll be able to bolt it on.

I bent the stock guages so that they lay flat and give it a sleeker look - wiring it will be difficult as I'm trying to make sense of the wire harness.

Overall I think it'll look good once I get her together. Still have to make the electrics tray that I'm going to hide under the seat leaving the engine bay / pods with an open look. Would also love to get some rear sets eventually...
 
Last edited:
Cheap cafe headlight ears

Cheap cafe headlight ears

I use the $15 steel headlight ears available from Mike's XS and others. Available in chrome or black. Also, be careful not to bend the gauge cables too much by tipping the clocks back. I tried it and had a little wobble in the needles.

I have run Tarozzi clip-ons on my '78 550, and they don't hit the tank if you don't angle them back too far.
 
Last edited:
You must log in or register to reply here.

Similar threads

G
1982 GS1000 Z US Version
Replies
10
Views
247
slayer61
slayer61
A
1981 gs650g project
Replies
5
Views
188
jdub6092
jdub6092
DR Payne
1983 GS550E: The Scenic Route
2
Replies
22
Views
542
DR Payne
DR Payne
exdirtbiker
2 GS750 engines
Replies
5
Views
165
exdirtbiker
exdirtbiker
S
1979 GS850 fork alignment questions
Replies
1
Views
81
salty_monk
salty_monk
Back
Top