GS550 with 650 Block Project

[Suzuki_Don]

Also don't forget to change the camshaft sprockets. You can use either the 550 or the 650 cams in the 650 head. The 550 cam might have a bit more timing as they are an earlier camshaft. By '81 they were pulling back on the timing with EPA and all that. Whichever shaft you use you MUST use the 550 camshaft sprockets. They have a different number of teeth to the 650 sprockets. From memory the 550 is 30 teeth and the 650 is 32 teeth.

[msdosp1mp]

In that case, I'm going to use the 550 camshafts, as they seem to be in perfect shape for a 34k mileage motor. Are you using the stock exhaust/airbox on your setup?

[Suzuki_Don]

In that case, I'm going to use the 550 camshafts, as they seem to be in perfect shape for a 34k mileage motor. Are you using the stock exhaust/airbox on your setup?

The stock exhaust will fit OK. I am using a 4-1 which was on the bike when i got it. Use new exhaust gaskets.

The stock airbox will not fit as you will have to fit 32mm CV Mikunis to the 650 head and the airbox rubbers are too small to fit over the CV air intakes.

Buy an airbox off a 650E model and it will bolt straight onto the frame and your airfilter box will line up with it perfectly. No probs. DO NOT buy one from a 650G (it is totally different and will not fit).

[msdosp1mp]

I've already got a 4 in 1 pipe thats going to be used, but what are my options as far as individual filters? I'd really like to run the APE 005-121 as a first preference due to price, but the K&N RC-2344 seems to also be a good size. No EMGO for me What did you have to go through with the carburetor jetting? Dynojet?

http://gszone.biz/carbs.html APE

http://www.clemmonstrading.com/servl...-fdsh-8/Detail K&N

More questions soon to follow I'm sure

Thanks everyone,
William

[Suzuki_Don]

Some jetting changes will need to be made if using POD filters. I am using the stock air filter system with original foam filter so no rejetting for me.

[brveagle]

I've already got a 4 in 1 pipe thats going to be used, but what are my options as far as individual filters? I'd really like to run the APE 005-121 as a first preference due to price, but the K&N RC-2344 seems to also be a good size. No EMGO for me What did you have to go through with the carburetor jetting? Dynojet?

http://gszone.biz/carbs.html APE

http://www.clemmonstrading.com/servl...-fdsh-8/Detail K&N

More questions soon to follow I'm sure

Thanks everyone,
William

Is the pipe for a 550 or 650? They have slightly different header pipe ID's.

Also, I went with stock airbox with drop in k&n. No problems and holds an idle well. I jetted mine by doing plug chops and running to local bike shop to buy jets.

[msdosp1mp]

The pipe is for the 550, but I plan on using the 650 gaskets. Might be a bit loose eh?

[brveagle]

The pipe is for the 550, but I plan on using the 650 gaskets. Might be a bit loose eh?

You'll be fine. Might have to have play with the header to get it to seal perfectly, but it'll work

[msdosp1mp]

The ball is rolling, I should have the rest of the top end by next week, thanks to duaneage. Thank you lots! For now, I've just been cleaning up the bike, as its alot easier to do with most of the engine taken apart. Stay tuned for more updates.

[msdosp1mp]

Ok, the parts that i've ordered have come in the mail. I'm going to start the grinding process on the crankcase later today I think. What brand of gaskets(head and base) are going to offer me the best reliability and leak resistance?

Thanks,
William

[doctorgonzo]

Ok, the parts that i've ordered have come in the mail. I'm going to start the grinding process on the crankcase later today I think. What brand of gaskets(head and base) are going to offer me the best reliability and leak resistance?

Thanks,
William

I think most people will tell you OEM. I put Athena gaskets on mine (upside being price), which some have had problems with, but none for me so far.

[TwistedRoads]

I've got an extra 650 head and pistons if you're interested e-mail me at hotmail

[msdosp1mp]

I've got an extra 650 head and pistons if you're interested e-mail me at hotmail

Thanks for the kind offer, but those have already been acquired. But that does bring something else up, I need a nice clean rack o' carbs. Anyone have a bargain?

Thanks,
William

[msdosp1mp]

Ok, so its been awhile since i've posted any updates on this. I'm looking to fix the cylinder head up a little bit and was wondering if the 550 valve springs are the same as the 650? Webcamshafts sells a set of better quality springs for the 550. Also, which GS's share the same head nuts? The APE set looks nicer than the pitted chrome pieces. Otherwise, I am going to finish this and have a faster 550, hopefully :P