GS550 Custom...

[Bopi]

So do you see any problems with this design

[Bopi]

ya know, for $400 bucks, i'd be better off getting the lathe fired up and make a set of my own.

[Bopi]

ya know, for $400 bucks, i'd be better off getting the lathe fired up and make a set of my own.

Also isn't there a groove cut into the shift shaft '
i'd have to "carefully" cut another one at 12 oclock.


wrong button Edit/quote

[ron bayless]

Also isn't there a groove cut into the shift shaft '
i'd have to "carefully" cut another one at 12 oclock.


wrong button Edit/quote

HERE ARE ALL THE ANSWERS TO YOUR QUESTIONS.YES THE DESIGN WOULD WORK FOR THE SHIFTER SIDE.THAT IS WHAT i HAVE FOR MY BIKE, EXCEPT I USED ROD ENDS,not the turnbuckl thing.I (my buddy) welded a 5/16 threaded bolt to and end of a small tubing on either end.The bolt threads perfectly into the female threads of the rod ends and the bolt can screw in or out a little bit to give some adjustment.On the shifter side you just cut down the stock lever and reuse it.no, it doesnt have a groove.On the brake side that wont work.The brake side the lever goes forward,not down.I heated it up and after many attempts got it to go down,out and slanted at the right amount to work with the same design linkage as you had in mind for the shifter side.Once again i used rod ends,but either way will work.So, that looks like crap on the brake thing.So, make yoyr own splined coupler.Not on Jim's customs site if you take the splined shaft on our brake side,cover it with a tube,then extend the tube out about 2 3/4 inches it will clear the cases and could be connected with linkage from the front to the back.Take off your crash bar engine gurards,either side will do.Make another mounting bar like the one that attachhes to the 2 engine mounting bolts.I used 1 and 1/2 inch wide and 1/4 inch thick i believe.Only it has to be a much longer rectangle now.The bottom of it needs to come down to near the bottom of the engine case.You then do what i did or similar and i used a bolt,about 8 1/2 inches in length, it has a head about 1 inche in diameter.Weld the head of the bolt to the bottom of your rectangle.Drill 2 more holes at the same place the original crash bar bolt holes were.Simple,lay the old plate over the new rectangle and trace the holes.Now, the pipe thick walled structural tubing,probably doesnt have to be that strong, is the part used for the brake side splined coupler.It will be about 2/12 or 2 3/4 inches long.Just hold it up against the brake splined thing with the pinch bolt and see where it comes out to to clear the cases.Cut off the old brake lever completely.Weld your tubing piece to that.Using the tubing open end for a pattern trace the 1 inch circle on a piece of paper.Then make a pie shape form either side of the circle down to whatever distqance it takes the clear the case at the bottom.A sort of triangular rounded piece now.Cut it out,weld it onto the end of the tubing piece.drill a hol at the bottom of the pie shaped piece,secure one end of your linkage to that,go forward to the other end.The bolt is too small, so take another length of tubing the same size you used for the brake thing and cut it to fit over the bolt.Thes 2 should be as tight a fit as you can find.This pipe thing turns now over the bolt like a hinge sort of.You can either make this whole front pipe piece the turning part/pivot part or weld it to the bolt and use only about the last outermst 1 inch piece for the pivot part.Now, the linkage coming from your new brake coupler will attach to the bottom of your new front control pivot piece.You will have to take some flat stock and weld to the pivoting part and make a hole in the bottom of it for your linkage to hook to.The brake coupler needs to angle towards the front of the motor a little bit.So when you push down on the new front brake pedal the klinkage moves from the front of the bike towarsd the rear of the bike.The brake splined coupler area makes about 1 inch of a total rotation,so you give it a head start by advancing it forward, then push the pedal down and the linkage moves it rearward and thereby applies the rear brake fully.I made some cool arms for new shifter pegs and brake pegs and intend welding them on top of the pivot pieces on either side.Until you sit on the bike,put your left toe about where you think the shifter peg should be and have someone mark it, you dont know how long the linkage should be.The same on the brake side.There,that's it.Probably 20 dollars for rod ends,about 20 for materials,?$ for pegs,welding time,stock extra parts to make the new ones out of, probably for less than 100 dollars you can make a set of raw controls that fit only your bike or others exactly like it.

[Hector Penalosa]

Here's my 1980 Suzuki GS 1100E .

Yeah the rear tire has to go. I have no Idea what the DPO was thinking.. However, I do have an 81 GS450 that I will be accepting as a parts donor with two good wheels and tires.

As far as laughing at my plans, well... laugh all you want. Im not worried I guess I have more ambition and hope for MY Bike than you ever will.

Cheers!

Hi Minime, I like it when someone can think "out of the box", so to speak.
I bought my Suzuki GS 1100E w/ the intention to modify it's looks. Which I did. Here's a picture of it . Hopefully it may give you some ideas.
I'll be waitng patiently to see the end result of your project.
GO TEAM! H

[ron bayless]

Hi Minime, I like it when someone can think "out of the box", so to speak.
I bought my Suzuki GS 1100E w/ the intention to modify it's looks. Which I did. Here's a picture of it . Hopefully it may give you some ideas.
I'll be waitng patiently to see the end result of your project.
GO TEAM! H

wHAT A BEAUTIFUL BIKE YOU HAVE.

[badbrown]

I gotta stop working 12 hr days. My eyes are playing tricks on me.

[minime]

Lots of change...

Well, I picked up a parts bike (GS450).

I took the wheels, front brakes, side stand, throttle tube, headlight basket, clutch lever, Speedo/Tach, and misc. other bits and added them into the 550 project.

I was going to originally add the speedo into the center however I was having a hard time with a mounting bracket. I then decided to use the speedo and tach from the 450 and have both running minus the center warning lights. I liked the 450 ones better because they had individual covers for the rear unlike the 550.

I swapped headlight askets becasue the 550 was real ratty and held together by rivits. Sure I have a smaller light now, but it straightened out my turn signals and looks a lot better (Its being painted Flat black)

The front end needed new bearings so I ordered them from Z1 and installed them today. Didn't take more than an hour and they fit PERFECT!

This made progress getting the front wheel swapped in. I was in the process of putting in the rear wheel and want to swap chains as well... So I need to wait till tomorrow as I left my impact screwdriver at work and cannot remove the case without it.

So far I am still @ minimal investment. I had to shell out extra dough for the bearings... but what the heck. It's a saftey thing.

Havent done the math but I think I am just a tad over $300.

Here are some pics:

[ron bayless]

Well, I picked up a parts bike (GS450).

I took the wheels, front brakes, side stand, throttle tube, headlight basket, clutch lever, Speedo/Tach, and misc. other bits and added them into the 550 project.

I was going to originally add the speedo into the center however I was having a hard time with a mounting bracket. I then decided to use the speedo and tach from the 450 and have both running minus the center warning lights. I liked the 450 ones better because they had individual covers for the rear unlike the 550.

I swapped headlight askets becasue the 550 was real ratty and held together by rivits. Sure I have a smaller light now, but it straightened out my turn signals and looks a lot better (Its being painted Flat black)

The front end needed new bearings so I ordered them from Z1 and installed them today. Didn't take more than an hour and they fit PERFECT!

This made progress getting the front wheel swapped in. I was in the process of putting in the rear wheel and want to swap chains as well... So I need to wait till tomorrow as I left my impact screwdriver at work and cannot remove the case without it.

So far I am still @ minimal investment. I had to shell out extra dough for the bearings... but what the heck. It's a saftey thing.

Havent done the math but I think I am just a tad over $300.

Here are some pics:

looks like you are coming along.my bike is worth about 1500 dollars.i have 2500 in it now and am still rebuilding the motor,then i gotta paint it.Yep there are no explanations for mans little passions.We dont need any.Life is too short to not spend some of it on fixing up a motorcycle!

[Nerobro]

I'm with you brveagle..

[Steve]

Looks like you are making good progress on a wonderful project.

The only thing I have to offer you is about your tail light idea. Yes, the trailer integrator will work, but be aware of one thing...when you turn on the turn signal, the front and rear will flash at the same time, as they should. However, when you turn on the brake, they will flash opposite each other. That is, the front will be on while the rear is off, then the front will be off while the rear is on. This is NOT a defect with the integrator, it's just the way they work. 8-[

Keep the pictures coming. \\/
.

[minime]

Update:

So here goes: So far I have made some excellent progress and hope to have her riding (Not finished, but at least road worthy) by next week.

I wrapped my seat and fitted the 450 tank as it is a little more "slender" than the 550's tank. I painted everything flat black. I am continuing progress on the forward controls however I am at a stand still due to the chain being off the bike.

I am waiting for my pods, rear sprocket, and fork seals to come in. I got the motor running, its just a bit on the rich side on the left bank so I need to tune the carbs in. Possibly take them off and clean them.

The integrator works great, and all but the headlight is in for the electronics. I still need to fab up some side covers and a switch panel for all the accessories (Blinkers LOL) under the seat.

Graips are still being sanded down (They are aluminum) and will stay brushed with black ends. Mirror will be added for inspection purposes, but I dont like mirrors so it will promptly come off. (spare me the lectures about riding w/o mirrors)

The plate on the bike was just for fitting up the bracket and to see how it will look in that position. I still need to paint the bracket and fab a light.

[80GS1000]

Looking better. Do you have side panels to cover up the battery and electronics?

[minime]

more pics






Side covers will be made eventually... Parts tomorrow. More to come...

[Fanning]

Looking good man. I like the progress you've made. Boy do I love watching projects come to life, not sure what it is, but I get a big kick out of it. Hope she rides as well as she looks for ya. Can't wait to read the final report about her.

Fanning