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1983 GS550E Project

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    1983 GS550E Project

    Well a couple weeks ago I picked up a new bike that I can ride on a more frequent basis and not worry about parts breaking.. lol. I know you are all going to hate me, but I picked up a 2005 Yamaha R6 Raven. I know its not a Suzuki, but my family has always lived by Yamaha on snowmobiles, and I got a really good deal on it so i broke down and bought it. And I have to say, I LOVE it. Anyways, now that I have a DD bike, its time to start working on the GS for a full restore. Here are the plans for the restore:
    1) sandblast frame and all metal components (brakets, mounts, etc). And hopefully get the frame powdercoated and possibly powdercoat the smaller parts myself.
    2) replace any wearable parts since it will be a lot easier to change it while I am putting everything back together. New parts will include; chain, sprockets, throttle/tach/clutch/speedo cables, brakes & rotors, battery (needs a new one), possibly clutch assembly if finances allow it, and anything else I come across during the rebuild.
    3) as much hardware that I can get replaced will be replaced with stainless where possible, and just new where I cannot find stainless. I have a good selection of metric stainless hardware at work.
    4) K&N filters with carb rebuild and jetting by a local reputable shop in my area. There is no way in hell i am fighting with that air box again. it was a royal PITA to get out, and I am very surprised it didnt break while I was trying to get it out.
    5) Replace all broken plastics and repaint all plastics, tank, etc.
    6) Since finding original unbroken/scratched plastics is nearly impossible and expensive, I am going to just repaint the plastics and have a buddy of mine make me factory duplicate graphics to make it look as original as possible. I will be going with the black/white/red scheme.
    7) Depending on how finances are with the build, I want to attempt to upgrade the rear tail to a mid 90's tail that I will be getting from a buddy of mine. I will also hopefully be putting in an integrated tail light along with it to clean up the rear end.
    That is the plan so far, and as the project comes along, I am sure I will be changing things. It will be a very slow going project as money is tight right now. I will post updates as it comes along.
    Now that I've bored you with a long drawn out explanation, here are some pics:
    The bike when I first bought it:


    Couldnt stand the white/blue so I rattle canned it for a cheap temporary fix:


    More pics in following posts

    Any input is appreciated.

    One quick question... attached to the front bottom of the airbox was a rubber line that went down towards the ground and it appeard as if it hit the exhaust b/c it was completely melted. Does anyone know where this was supposed to go? I think i may have found my vaccuum leak that I had.

    Thanks.

    Kenny
    Last edited by Guest; 08-13-2009, 10:08 PM.

    #2
    After about 3 hours of work today:



    My make-shift work area... no garage, so I converted the front porch into a bike garage. There is just enough room to get on either side of the bike and even enough space for my tools.. lol

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      #3
      And a quick pic of the new bike:

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        #4
        quick random question... how much work is required to put the gs1100 motor in there?

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          #5
          Originally posted by klarowe View Post
          One quick question... attached to the front bottom of the airbox was a rubber line that went down towards the ground and it appeard as if it hit the exhaust b/c it was completely melted. Does anyone know where this was supposed to go? I think i may have found my vaccuum leak that I had.

          Thanks.

          Kenny
          This hose should have had a plug in the bottom and is a drain for the air box in case whatever gets in there. During my GS550E carb rebuild, I pulled this plug and discovered a host of gas/oil/water/whatever in there. It filled up a bit once more, but after the rebuild, it has been clean and dry since. If the hose is still long enough, clip off the end and plug it with something suitable and you are good to go.

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            #6
            Odd about the airbox
            it is very easy to remove and reinstall but you need to remove bolts from the suspension to drop the flat piece of metal benetht he battery tray.

            One would go insane otherwise.

            keep sending us pics we love pics

            Comment


              #7
              Originally posted by klarowe View Post
              quick random question... how much work is required to put the gs1100 motor in there?
              eww blasphemy horror of horrors.
              I think one of the guys here put a 750 motor in that frame

              try searching for it I cant recall his name

              Comment


                #8
                yea, i had a feeling you would have to take out that flat piece of metal, but it was getting late, so a little (ok, a LOT) of elbow grease and i "convinced" it to come out... lol. The 1100 motor idea is more of a joke... as much as I would love to do it, i know its not going to be a simple bolt-up job.. lol

                Comment


                  #9
                  8/14/09 Update

                  Got some more torn down today... should be ready to pull the motor tomorrow (hopefully in 1 piece), and possibly get the front forks off.
                  Updated pics:



                  Comment


                    #10
                    Parts, parts, and more parts:



                    Kenny

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                      #11
                      sorry for the delay, but I have been quite lazy lately.. lol. Finally got a little more done on the project. took all the small parts to work and blasted them. I am not 100% sure when I'll be able to powdercoat them (hopefully very soon) so I put them in bags to keep them from developing any rust in the meantime. I also finally got around to popping off the handlebars and triple tree to separate the front forks and frame. let me tell you, the left handlebar was a BIT**. I have to check the handlebar closely to make sure it isnt bent from the massive beating I gave it to get it off.
                      Updated pics:




                      If all goes well, I will hopefully be getting the powdercoating gun this week and setting up the oven this weekend.

                      Kenny

                      Comment


                        #12
                        another update:
                        Got most of the parts powdercoated and got the frame/swingarm painted. Everything came out really good. I have to say, the harbor freight set up worked pretty damn well. And the ghetto oven I used worked fine. Now to start reassembling what I can.
                        Pics:



                        Comment


                          #13



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                            #14
                            Looks great...can't wait to see what you might do with the stock handlebars...I'm trying to figure out what to do.

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