78 GS550 cafe project

[78gscafe]

Well today was another longs day. Made up some intake manifolds to try and fit the GS750 carbs, but soon realized the actual problem. These carbs are from an 82 GS750 and I need something from a 77-79 GS750. The difference between the years is that the later carbs are butterfly and only have one throttle cable, and the early carbs are just larger versions of my existing GS550Es. I still can use the manifolds on the earlier carbs but now I need to find a set. On the positive side my Vipex shocks showed up. I bought a set of the Vipex Road Race CBF shocks. I am modifying everything as it is and I couldn't wait for the GS versions. They are amazing, and very stiff. It took awhile for them to show up, but so far they seem well worth the wait. I got more wiring done. I also finalized the mounts on the exhaust. Version eight of the gauge mount was also finished but it placed the gauges higher than expected. It makes the front end seem very tall. So I guess there is going to be a version nine. The battery strap and the rear brake reservoir were also put in. So all in all only a little closer to completion but without carbs start up is looking a lot farther off.


http://community.webshots.com/album/559109513pyYHsv

 

[78gscafe]

Finally got the bike running. There are a few problems, but hopefully they will all get worked out this week. I am going to have to get someone to paint the tank and tail, because the current paint is not holding up very well. I also did a rough weigh in. It came in at 440lbs wet with a full tank of gas which is a considerable drop in weight over stock without stressing the structural integrity of the frame. Ended up just trying the stock carbs to try and start it. It ran pretty well considering I did not jet the carbs (new ones are in the mail) and just adding some fuel. The brakes are amazing, and the Vipex shocks are rock solid. It feels close to a hard tail under passive riding, but as soon as I pushed they really made an impression.


http://good-times.webshots.com/album/559238695GXRHtr

 

[t3rmin]

Looks great!!!

 

[78gscafe]

Still need to finish the tail section, but it finally looks like a bike.

 

[Zooks]

WOW. I plan on sleeping with a picture of your bike tonight is that alright?

I love it. I want to see it complete. Finish the tail section - HURRY UP!!!

 

[Dignan]

How'd you get the 450 tank to sit so low on the backbone? I have the same tank.. I had to flare out the front edges to clear the frame and cave in the underside of the rear to drop down a bit on the rubber pad. Mine still sits ~1" higher than the rear section of the frame.

I dig your bike big time. Too bad (for me) that you're so quick. Mine is going to look a lot like it when I'm done..

 

[Ninja_Lancer]

What was involved in the GS1100 swingarm swap? Was it a bolt on?

Thanks!


N_L

 

[78gscafe]

Well I only flared out the front edges of the tank 1/16" on each side. What year is your bike? I didn't have to do anything else to make it fit. I did however make different stops for the front end so it wouldn't dent the tank.

The swing arm conversion is a bit dicey. The gs1100E swing arm fits perfectly between the frame, but you have to drill out the swing arm pivot holes. It involves a 16mm or 41/64" drill bit and a steady hand. I set it up on the drill press with a support under the steering head. Then clamped and the frame square to the boss. Then the part comes where you cross your fingers and go for it. You also need the swing arm pivot from the gs1100E, but it will be a bit long so you might want to turn it down or make spacers. I made spacers, but am going to turn it soon.

The tail section is in its final stages of sanding so hopefully in will be on shortly. But I did have a hiccup today, the sprocket on the transmission backed out and cut the clutch cable so 141 miles in and its back to the garage for a week.

 

[Dignan]

Thanks for the answer. I also have a '78 750. I haven't tried too hard to fit it yet, I think a little "coaxing" with the BFH and it'll fit like I want it to.

 

[78gscafe]

Well here is an updated photo. I made some Lexan panels to cover up some of the wires. They were getting a bit messy.

and here is the rest of the gallery.

http://good-times.webshots.com/album/559464885zSahZB

 

[80GS1000]

Nice lookin' bike there!

 

[Guest]

MAGNIFICENT work!!!! \\/

 

[78gscafe]

The new gauges showed up. This solved the tall look of the front end. New brackets were needed, but now they clear the banjo bolt and clutch cable. Some barend mirrors are also on the way.

 

[Guest]

So, uh, where do you live?? I want to buy some rear sets and front peg mounts for my EZ, and have you weld them up!!! :-D I am on the never ending quest to drop weight from the Ole Girl.

 

[petelardo]

Not that you need any advice from me, but if you want to try painting the gas tank again, try using (just about any brand) engine paint. It is tough and durable, and designed to withstand the effects of gasoline and oil. If you find a quality brand, you should also be able to find a matching clear coat, which will protect the color coats, and add depth... I haven't had much luck mixing brands over the years; too many problems, too many ruined paint jobs...

 

[78gscafe]

Yeah, the paint is waiting as of now. I just wanted to spray it down in order to ride this summer. I will probably get someone else to do the finishing job. This will more than likely happen over the winter along with some engine modifications. The idea is to strip the bike down and while the engine is out powder coat the frame and misc parts as well as get the tail and tank painted. For the engine mods the thought is to do the 740cc conversion that brveagle did along with upping the compression to 11:1. All the parts are shipped, so just waiting for them to show up. Oh and I reside in Wisconsin.

 

[Billy Ricks]

Nice job you've done. One of the better cafe bikes done here.

 

[badbrown]

You did alot of nice work. I think you should try to tack on the stock rear cowl, instead of leaving it blank. The 550E rear cowl is one of the better looking of the GS line IMO. Otherwise I love the MADMAX'ness of the bike, Very evil looking good job.

 

[78gscafe]

The bike is running again and this time it runs like a champ. I noticed that the Vipex shocks were slightly bent in. So I had to make some spacers.

That is what you need to make to adapt the CBF Vipex Shocks to a gs550. So don't worry about waiting for the gs versions just order yourself the cbf shocks. They are firm but perfect for my needs. The tail is almost done. I haven't put the top coat or the stripes on yet but that will happen over the weekend.




And sorry but I prefer the lexan panels.
Here are the rest of the galleries.

http://good-times.webshots.com/album/559624595DgfVhW

http://good-times.webshots.com/album/559624008ZIcmSu

 

[jlgace]

I like your style. Very nice job. You're motivating me to get at my own cafe project I've been putting off for a while. Thanks.