An absolute beginners guide to a 1980 GS550 engine

[Nbing]

Hello everybody!

So with the start of summer break (I'm still in high school) i figured it would be a great time to finish on this project I started. You guys already helped me clean and fix up the carbs but now its time to get the engine back up and running. I know you guys say it will take about a weekend to get done but I feel with the amount of clumsiness I have I have managed to make the project even harder for myself. I'm pretty sure how I've been doing things are incorrect and would really appreciate if you guys could help me out in simple terms like you did on my carb forums. The engine was originally going to get painted so somebody told me that the engine must be split open and emptied out to just the case.

The story as follows. Yes I am young. Yes I made mistakes.

The case I have was scratched and disgusting beyond belief, I have had over a straight week of work on just degreasing the engine with zero luck. Ive tried brushes, sandpaper, drills, pads, the list goes on and on. So I ordered a separate case. I just want to know whats next. What do I have to order. Hopefully I can make this thread into a very simple picture by picture tutorial for others to follow. I think if I can get it then a lot of people can get it. I'm in all the AP classes at school but its just something with this engine im having the hardest time figuring out, I think I may be over complicating it. But I love a challenge and a puzzle.
During the tear down

Where it sits right now:

First stupid question: Is the oil pump missing?

 

[scottp]

Thanks for starting this thread. I'm doing an '82 550 top end rebuild so will be watching this (so you can make the mistakes first )!

 

[Nbing]

You're very welcome! I plan on starting to get the shop cleaned up tomorrow and organize everything in my garage to bring this baby back to life before the end of summer hopefully. As soon as I get an idea of what to order and from where ill get the pieces shipped. Yes Yes, i know its going to cost me alot because i screwed up in places, but I would like a bike that will last and I fell in love with the design and sound of these bikes

 

[tkent02]

You're an A&P, you took it apart because it wasn't shiny enough, and now the oil pump is missing?

A real A&P would have fixed it with a pen.

 

[Nbing]

By AP i mean I love challenges and testing new things. Not sit behind a desk all day with a pen I wanted the shiny factor but after that forum you guys talked me out of it because I want to ride it more than detail it every day. But what I care about most is getting the engine fixed back up and running like new.

 

[Steve]

Not sure how "AP" tranlates into "I love challenges and testing new things", but I am not sure that tkent is clear on your meaning, either. :-k

His "A&P" refers to "Airframe and Powerplant", as he is a pilot, and that would be a familiar term to him.

Please explain your version of "AP".

Also not sure why anyone would tell you that you had to strip your engine to bare cases just to paint it. At the very worst, you might want to remove it from the frame, to be able to spray into some areas that would be shadowed by the frame or exhaust system, but I have never even removed the exhaust to paint any of my engines, let alone remove the engine or strip it down. True, they are not show bikes, and I consider the paint job a "20/20" job. That is "20 feet away, at 20 mph, it looks great." :encouragement:

.

 

[Guest]

*Advanced Placement

 

[huntb]

In highschool AP stands for Advanced Placement which translates to the harder classes for smarter kids. Some of these classes may even be eligible for college credit.

 

[Rob S.]

In highschool AP stands for Advanced Placement...Some of these classes may even be eligible for college credit.

I thought they usually were.

 

[JEEPRUSTY]

Not Academic Probation?
Nice write up

 

[gustovh]

I have a complete 80 550L engine less valve shims, if you need anything. So.........crack open the manual and get to work, it has pictures of things like oil pumps and clutches and how they work. I admire the thought of a pictorial, and if you actually finish it, I may include it in my class.

V

 

[Nbing]

Before cracking into this project are there any special tools that I should get order? like the spring depressor or tools for the pistons? What gaskets do you guys find best to use for the engine?

 

[terrylee]

Always use oem, especially the base and head gasket.

 

[Nbing]

So after the reading the manual Id have to grab some tools such as the spring compressor, shim tool
http://www.ebay.com/itm/Universal-M...hash=item3f4d183a0d&item=271876373005&vxp=mtr

http://www.ebay.com/itm/SUZUKI-VALV...628-/161722821705?hash=item25a76e6c49&vxp=mtr

So how about these for everything else:

http://www.ebay.com/itm/Suzuki-GS-5...4&pid=100005&rk=1&rkt=6&sd=161667170852&rt=nc

And for the head this:
http://www.ebay.com/itm/SUZUKI-GS55...nos-/380645752029?hash=item58a0413cdd&vxp=mtr

 

[Nbing]

Alright, so everything is in order in the garage, engine is ready to be transferred to the new case. The gears all move very nicely however I was wondering if I should use any sort of procedure to clean the gears inside before resealing and everything since the case has been open for awhile. I found out the oil pump is all good and figured out. I was wondering, do i just pick up and drop crank and gears into the new case? or is it not that simple. I am going to make a run to the hardware store to get an impact screwdriver to take out the counter sunk screws holding together some of the stuff inside. Should post pics tomorrow of what I can put in the new case and get as close as I can to resealing it. Any opinions on what to use for sealer?

Edit: after researching everybody is saying either A. spray with brake cleaner to get debris off off the gears. Or B. Soak in hot water and dawn dish soap and then use the air compressor to dry everything off and lastly spray down with wd 40. or C. Carb cleaner on everything before inserting. What do you guys find is best?

 

[eil]

Did I read that right, you bought brand-new cases because you couldn't clean the old ones to your satisfaction?

That valve spring compressor might work. It's certainly the cheapest one I've seen. You can go cheaper and pick up an 8" C-clamp from Horrible Freight and cut a window into a piece of PVC pipe or an old socket. (I used an oxygen sensor socket on my 850, but I don't know if that's too big for the 550.)

That valve shim tool is the right one.

I can't imagine how you've managed to disassemble the engine so far without an impact screwdriver!

Search the forum for threads on case sealant. There are many options, almost any will do.

As for cleaning the gears, solvent of your choice followed by compressed air should work fine. If they look clean, then they probably are. In the future, don't leave a disassembled engine hanging out uncovered in the garage.

Crank and gears should drop in to the new case, but follow the manual and measure everything, especially bearing clearances.

 

[Nbing]

Nope, I had to get a new case because it was cracked. Took it to my dad's friends shop to get it welded and didn't have any luck. I'll post pics of the cracked one tomorrow. Bike must have gotten in a crash because even the tank was dented before restoring it.

 

[eil]

Ah, okay. That makes more sense.

Get your base and head gaskets from Suzuki. You can try your luck with aftermarket gaskets just about anywhere else. They're fairly easy to change if they do leak. Check out the website for Z1 Enterprises, they tend to stock decent aftermarket stuff for your bike.

 

[charnotx]

Sorry to revive an old thread... I guess this engine build stalled??

 

[roeme]

...if not abandoned altogether.