First ever bike rehab attempt: 1980 GS550

[Redneck]

yes, tons of fun.... until you take off one part to reveal a worn out this, or a broken that..... and simple green and scrubbing.... and gunk engine degreaser and tryin to "make " a special tool to clean a certain crevice. and 20 more dollars for more purple power cleaner and more PB Blaster. Then you start to get a "vision " of what you are tryin to do with the bike, and then THIS certain part is not good enough, and THAT part is the one I must have....and holy crap, i have been polishing and painting parts for six hours and that was just one wheel and a few other lil things. then you start painting bolts, cause they are rusty and look like ****, but ya gotta getem shiny with a wire wheel first... then primer,,,, then paint.... then you obsess that the paint will crack on em when you torque em down, so you better bake the paint...... ha ha ha ha (BUT I WOULD NOT HAVE IT ANY OTHER WAY!!!) I am enjoying my rebuild quite a bit, and as I near having fully stripped, painted and polished rolling chassis again, I am a step closer to realizing I am making a bike that is all mine and I dreamed up. It is not a super perfect rebuild, but I am getting some pretty good results. Pretty cool. Cant wait to ride it already..... good luck, best wishes.. Its a beautiful obsession.....

Aint that the truth brother.

As far as your tank goes. I have done the vinegar method on an old worn out tank. Lets just say wow it really works. Then let me empahsize that as soon as you dump out the vinegear get some kind of protective coating in side or it will flash rust within the hour. My recommendation is if you plan on putting in a liner then have the Por 15 kit standing by if not I have heard someone sprayed the inside of the tank with WD-40 ...though I can't say for sure. Good luck and have fun.

Paul

[bsullivan]

Interesting...and cheap. Can you expand on the vinegar method or link to some place that can?

I'd never heard of POR 15 until 5 minutes ago when another friend suggested it. I have no idea what it is, but I'm going to look into it.

Thanks!

[bsullivan]

Replacement petcocks look like mine--they don't have a switch. Am I missing something? How can you possible turn the valve without a switch? Supposed to use a key or a screwdriver or something?

[Redneck]

Interesting...and cheap. Can you expand on the vinegar method or link to some place that can?

I'd never heard of POR 15 until 5 minutes ago when another friend suggested it. I have no idea what it is, but I'm going to look into it.

Thanks!

It is as simple as it sounds. White or apple cider vinegar does not matter which ever one comes in the gallon jugs ... Block off the petcock hole and fuel sender hole so it is whater tight. Fill 1/2 way with vinegar and half a bag of aquarium rocks. Put a plug or seal on the fill hole. Your gas cap will not work because they are vented. Then Shake vigourously. Set it down and forget about it. Every time you walk by it give it a good shake then about 24 hours later turn it over to get the other side of the tank. 24 hours after that drain out all the old vinegar and fill it half way with fresh vinegar. (you can reuse the aquarium rocks) and Repeat. You may need to do this cycle once more but that should take care of your rust problem. Remember the last time you drain it then spray the inside with WD-40 or re install your petcock and fuel sender and fill with gas, if you refill with gas make sure you go ahead and fill it up to make sure the petroleum can be absorbed by all the metal to prevent flash rust. Good luck.

Paul

[bsullivan]

Great, thanks! Will report back.

[mike_of_bbg]

Yours is an 80, so it probably has the alien petcock they used that year. I also think the bolt spacing was different, unfortunately. Try some forum searches.

[Nessism]

It is as simple as it sounds. White or apple cider vinegar does not matter which ever one comes in the gallon jugs ... Block off the petcock hole and fuel sender hole so it is whater tight. Fill 1/2 way with vinegar and half a bag of aquarium rocks. Put a plug or seal on the fill hole. Your gas cap will not work because they are vented. Then Shake vigourously. Set it down and forget about it. Every time you walk by it give it a good shake then about 24 hours later turn it over to get the other side of the tank. 24 hours after that drain out all the old vinegar and fill it half way with fresh vinegar. (you can reuse the aquarium rocks) and Repeat. You may need to do this cycle once more but that should take care of your rust problem. Remember the last time you drain it then spray the inside with WD-40 or re install your petcock and fuel sender and fill with gas, if you refill with gas make sure you go ahead and fill it up to make sure the petroleum can be absorbed by all the metal to prevent flash rust. Good luck.

Paul

Paul nailed the technique here. I've never used vinegar before but use the same technique using phosphoric acid.

That lever-less petcock works well enough, plus they are the cheapest of all the Suzuki GS petcocks. Check Z1 Enterprises for a source if yours is knackered.

[bsullivan]

Yours is an 80, so it probably has the alien petcock they used that year. I also think the bolt spacing was different, unfortunately. Try some forum searches.

Will look--but how do I operate that sucker without the lever? Tiny little flathead?

[bsullivan]

Ugh. Nevermind:

http://www.thegsresources.com/_forum/showthread.php?t=176459&highlight=1980+petcock

"The dread 1980 petcock!" made me laugh. Also, I just learned my n00b lesson in searching the forum before troubling you all. At least I did so in my own thread!

Thanks.

[bsullivan]

Where the heck can I buy carb dip?!

[cowboyup3371]

Autozone, Pep Boys, Oreillys, any auto parts store should have some. Walmart will carry it too but may not have the big can.

[bsullivan]

Pepboys is a wonderland.