77-78 gs550 build

[Zafe]

Just picked up a gs550

has an oil leak on the left side i think its coming from the output shaft, is this common? is it just a seal? also appears that the clutch rod is bent some how

I searched for a manual on this forum, but I dont think my searching skills are good enough, if anyone has one on pdf it would be greatly appreciated

any diagrams or exploded views,


or part numbers.....

THANKS IN ADVANCE

[cowboyup3371]

Welcome. I didn't see Basscliff's welcome package on your other threads yet but when he does find you, go read it very carefully. Everything you need to know is linked from his site in addition to what you'll find here.

Good luck and throw your location in your profile in case one of us is close enough to come help.

[keman]

Link in my sig. Tons of info and downloadable manuals.

[Zafe]

im on like 8 forums, this one is by far the best so far.


thanks guys

[ChicagoBob]

That looks pretty good. You've got a nicely hammered tank and custom tail. Looks like it has side covers from a 750.

There is a seal on the sprocket shaft, which can be replaced without pulling he engine. See http://members.dslextreme.com/users/...ment_GS550.htm

[Joneman]

Just changed seals

I just did some similar work on my 78 550. See this thread: http://www.thegsresources.com/_forum...d.php?t=180416

I didn't change the clutch rod but got it straightened at a shop. I would not recommend taking it out if at all possible, because you have to take the clutch apart to get at it... although that would the proper way to go about it. It really wasn't too bad.

Good luck with the project!

[Zafe]

sprocket chain kit?

Thanks for the replies.


I just ordered all the seals, should be here next week, looking forward to the install.

Does anyone recommend a front/rear sprocket & chain kit?

[7981GS]

Thanks for the replies.


I just ordered all the seals, should be here next week, looking forward to the install.

Does anyone recommend a front/rear sprocket & chain kit?

I just pick up the phone and call Z1 Enterprises.
I tell them what final drive ratio that I want and they send the parts.

Daniel

[Nessism]

Most likely the chain came off and damaged the clutch pushrod, which has now damaged the oil seal and caused the oil leak. There are several threads in the archives on this topic. Basically, you need to pull the clutch hub out because the pushrod is installed from the RH side of the engine.

The Suzuki service part pushrod is two piece I believe. You will need both a new pushrod and new seals. You may be able to straighten the pushrod but don't count on it.

Good luck and welcome.

[Zafe]

Most likely the chain came off and damaged the clutch pushrod, which has now damaged the oil seal and caused the oil leak. There are several threads in the archives on this topic. Basically, you need to pull the clutch hub out because the pushrod is installed from the RH side of the engine.

The Suzuki service part pushrod is two piece I believe. You will need both a new pushrod and new seals. You may be able to straighten the pushrod but don't count on it.

Good luck and welcome.

ahh thanks nessism, the chain on it now is quite loose and I can see this is definitely what happened.

I just pick up the phone and call Z1 Enterprises.
I tell them what final drive ratio that I want and they send the parts.

Daniel

I plan on doing the stage 3 carb jets, and a 4-1 exhaust,
do you vary far from the stock ratios? do you recommend a ratio?

Thanks again all,

[Joneman]

I just thought I would add my 2 cents here, but I can't answer your questions. I've kept the stock ratio on my bike for pure simplicity and for assuming that if it was designed that way it must be the best way (50 rear/15 front).

I want to reinforce buying from Z1: I didnt realized they sold chains and sprockets and payed significantly more for the parts locally, except that my rear sprocket came from Iowa on account of it being discontinued (even more $). However, they have it on Z1!

From the look of your picture, you have a model B or C (spokes and rear drum brake). The sprocket is different for this bike then the E or other models (same year but with rear disc brakes and cast wheels).

Front Sprocket (verify what you have model first): http://www.z1enterprises.com/530-JTF...ocket-389.aspx ($10 on Z1, I payed more)
Rear Sprocket: http://www.z1enterprises.com/530-JTR...cket-1777.aspx ($36 on Z1, I payed $80 shipped)
Chain: http://www.z1enterprises.com/530-Cha...-Ring-380.aspx ($100 on Z1, I payed $130 for a regular DID O-ring https://picasaweb.google.com/lh/phot...eat=directlink, not the X-ring)
Chain Tool: http://www.z1enterprises.com/Chain-R...-Tool-382.aspx

Don't forget to grind the rivet head before using the chain breaker, as otherwise you will break the tool (I did!). Otherwise the tool is good enough for the occasional use.

Merry Christmas!

[7981GS]

I plan on doing the stage 3 carb jets, and a 4-1 exhaust,
do you vary far from the stock ratios? do you recommend a ratio?

Thanks again all,

If you mostly ride around town and seldom on the highway or over 70mph,
have them set you up with the stock final drive ratio.
If you like to accelerate a little more briskly and are not concerned about losing a few mpg and higher rpm's at 70 mph,
have them set you up with closer to 3.0 final drive ratio.
If you like to ride a bit more at highway speeds and like less buzziness at those speeds,
have them set you up closer to 2.65 or 2.70 final drive ratio.

Daniel

[Zafe]

I just thought I would add my 2 cents here, but I can't answer your questions. I've kept the stock ratio on my bike for pure simplicity and for assuming that if it was designed that way it must be the best way (50 rear/15 front).

I want to reinforce buying from Z1: I didnt realized they sold chains and sprockets and payed significantly more for the parts locally, except that my rear sprocket came from Iowa on account of it being discontinued (even more $). However, they have it on Z1!

From the look of your picture, you have a model B or C (spokes and rear drum brake). The sprocket is different for this bike then the E or other models (same year but with rear disc brakes and cast wheels).

Front Sprocket (verify what you have model first): http://www.z1enterprises.com/530-JTF...ocket-389.aspx ($10 on Z1, I payed more)
Rear Sprocket: http://www.z1enterprises.com/530-JTR...cket-1777.aspx ($36 on Z1, I payed $80 shipped)
Chain: http://www.z1enterprises.com/530-Cha...-Ring-380.aspx ($100 on Z1, I payed $130 for a regular DID O-ring https://picasaweb.google.com/lh/phot...eat=directlink, not the X-ring)
Chain Tool: http://www.z1enterprises.com/Chain-R...-Tool-382.aspx

Don't forget to grind the rivet head before using the chain breaker, as otherwise you will break the tool (I did!). Otherwise the tool is good enough for the occasional use.

Merry Christmas!

Merry christmas to you too, thats a great website, looking forward to ordering some parts in the following days,

Im trying to source a stage 3 performance carb jet kit, however i did not find one for the 77 gs550, does anyone use the kit for the 82 on the 77?

[Suzuki_Don]

Merry christmas to you too, thats a great website, looking forward to ordering some parts in the following days,

Im trying to source a stage 3 performance carb jet kit, however i did not find one for the 77 gs550, does anyone use the kit for the 82 on the 77?

The '82 kit won't fit the '77 model.

[Zafe]

sourcing parts

Started cleaning up the bike yesterday

took off the airbox, for the 50mm trumpets that should arrive this week,
started tucking away the wiring, and converting the hand controls to a hidden toggle and momentary switches, and grinded off most of the tabs i will no longer be needing.

ran into the problem that im going to need like 120 jets for the carb, filled up the tank with 100 octane, and it still breaks up mid-high rpm but it smells so nice.


anyone know of a performance carb kit for a 77gs550 ? or does anyone have one ?