Rebuilding the '80 Wes Cooley

[hampshirehog]

Nice job Russ - I hope that leaky tank spilling petrol didn't melt any paint. Seat looks great and your 'zorst makes a decent note without being too noisy. Just a shame it's a blue one.......

In your vid it looks like your front brake lines might rub against the mudguard - be worth checking out if you haven't.

[russr33]

Nice job Russ - I hope that leaky tank spilling petrol didn't melt any paint. Seat looks great and your 'zorst makes a decent note without being too noisy. Just a shame it's a blue one.......

In your vid it looks like your front brake lines might rub against the mudguard - be worth checking out if you haven't.

No it was coming from underneath at the fuel sending unit so no problem. The paint is original and not bad but will be painted in the future. I was actually thinking of maybe going with the red scheme since you don't see any in the states. I think the U.S. only got the blue and white scheme but I'm not positive.

Good call on the lines. I'll check that out.

[russr33]

Well still having problems with fuel sending unit. Problem is it's been messed with at some point and the actual hole in the tank is not round anymore. Has a few flat spots. Tried a sealer and it's better but still leaking. Back to the drawing board.

I did get the fuel level down where it wouldn't leak and took it for a ride. Took awhile as the clutch plates didn't want to release (sitting for 20 years will do that). Spent 20+minutes in first gear trying to get it to let go riding around my block. FInally took it where I could get some speed up and she finally released. Had about a 20 mile ride. Sure felt good

[simon kuether]

What ,may I ask ,is wrong with a blue one???? I've got a big blue one and am very happy with it.Only tossers have got red ones 'cause for some reason they think they go faster.VERRRRRRRR nice bike by the way.Getting to be quite a few 'S's around the traps lately.Good go.Here's ANOTHER pic of her sister,not totally stock,but pretty close.Cheers,Simon.

[russr33]

What ,may I ask ,is wrong with a blue one???? I've got a big blue one and am very happy with it.Only tossers have got red ones 'cause for some reason they think they go faster.VERRRRRRRR nice bike by the way.Getting to be quite a few 'S's around the traps lately.Good go.Here's ANOTHER pic of her sister,not totally stock,but pretty close.Cheers,Simon.

Ha! Absolutely nothing Simon. I'm actually quite fond of the color. Just thought it might be nice to have a color that was a little unique. Of course the bike itself is unique enough. BTW I've always thought of yours as an inspiration. Beautiful!

[jimfj]

As to your fuel leaking around the sending unit hole:

I just fixed this exact problem on a 550L. I fought it for two or three tries and several trips to the dealer for gaskets ect.

Here is what worked,

Take the sending unit out and clean the hole very well with acetone.
Put a good carnuba wax on the 5 (?) bolts threads that hold the plate on.
Screw them in all the way
Lay the tank on a towel so that the hole is as level as you can get it.
Mix up a two part epoxy. I used alluminum powder because i had it around to thicken it. I thickened to the consistancy of a heavy nacho cheese.
Pour around the hole and plate so that the epoxy comes with in a milimeter or two of the hole in the tank.
Let sit overnight and harden.

What you will have is a perfect seal and the bolts will come out with no problem because the carnuba wax acts as a mold release.

Put the sending unit back in and be sure to use the rubber gasket. ride and enjoy!

This repair has held perfectly for the past two months. The bike has been ridden regularly and the hot/cold has not affected the repair in the least.

Jim

[russr33]

As to your fuel leaking around the sending unit hole:

I just fixed this exact problem on a 550L. I fought it for two or three tries and several trips to the dealer for gaskets ect.

Here is what worked,

Take the sending unit out and clean the hole very well with acetone.
Put a good carnuba wax on the 5 (?) bolts threads that hold the plate on.
Screw them in all the way
Lay the tank on a towel so that the hole is as level as you can get it.
Mix up a two part epoxy. I used alluminum powder because i had it around to thicken it. I thickened to the consistancy of a heavy nacho cheese.
Pour around the hole and plate so that the epoxy comes with in a milimeter or two of the hole in the tank.
Let sit overnight and harden.

What you will have is a perfect seal and the bolts will come out with no problem because the carnuba wax acts as a mold release.

Put the sending unit back in and be sure to use the rubber gasket. ride and enjoy!

This repair has held perfectly for the past two months. The bike has been ridden regularly and the hot/cold has not affected the repair in the least.

Jim

Thanks Jim. Will try that and get back to you with results.

[nvr2old]

Simon, can you tell me where the smoked windscreen on your GS came from? I'm also building a '79 S model. I have the stock clear windscreen, but it's seen better days, and I would love to find a smoked replacement. Thanks.

[hampshirehog]

Simon, can you tell me where the smoked windscreen on your GS came from? I'm also building a '79 S model. I have the stock clear windscreen, but it's seen better days, and I would love to find a smoked replacement. Thanks.

If it's any use, I got one from these guys:

http://skidmarx.co.uk/section/screens/screens_headlight_covers/suzuki.html

[sharpy]

Simon, can you tell me where the smoked windscreen on your GS came from? I'm also building a '79 S model. I have the stock clear windscreen, but it's seen better days, and I would love to find a smoked replacement. Thanks.

Where do you live? There is a place at Albion, Brisbane that does them called AC plastics

[simon kuether]

Where do you live? There is a place at Albion, Brisbane that does them called AC plastics

You got it Sharpy.I rang Eagle screens,and couldn't get him to believe there was a '79 Suzuki that had a screen.Where you from Never old mate? I got a lot of bits for mine from Suziparts in Adelaide(expensive though) and from Alphasports in the States.Cheers,Simon.

[neilaction]

You got it Sharpy.I rang Eagle screens,and couldn't get him to believe there was a '79 Suzuki that had a screen.Where you from Never old mate? I got a lot of bits for mine from Suziparts in Adelaide(expensive though) and from Alphasports in the States.Cheers,Simon.

That's odd. I am pretty sure I have an Eagle screen fitted to my 80 ST.
79, 80. Surely the same screen?

[steve murdoch]

Simon, can you tell me where the smoked windscreen on your GS came from? I'm also building a '79 S model. I have the stock clear windscreen, but it's seen better days, and I would love to find a smoked replacement. Thanks.

If you are in North America, Zero-Gravity has the smoke windshield.

http://www.zerogravity-racing.com/sportbikes/suzuki_sptbks/165.htm

[vash_vts]

is that seat custom or the stocker that came with it? I'm trying to find me a groovy seat like that!

[russr33]

No it was not stock when I got it and then I had it recovered.