1978 gs550 - Consolidated Headaches

[VariableValve]

So, I've been making multiple threads about this little project of mine which is beginning to become a real headache.

Instead of constantly starting a new thread every time I run into a little issue, I thought it would be far less annoying for everyone and easier for me if I just kept it all here.

This is unlike the other projects/rebuilds which seem to be done by highly skilled problem solvers. Yes, I'm a noob. With that said, if you can offer some help it would be greatly appreciated.

Problem of the day:
So I need a new chain/sprocket badly on this bike. Obviously to achieve this I need to get my rear wheel off the ground and have access to the front sprockets.

1. Some previous owner removed the center stand, so I have to try and use swingarm stand. Unfortunately the low slung exhaust is in the way of this. Is there any way I could lift the bike without having to remove the entire exhaust? This isn't a HUGE hassle, but it does seem excessive to just lift the rear tire. I was thinking of lifting it with a jack but that seems a bit unstable...

2. I can't seem to remove the cover for the clutch assembly/front sprocket. After MUCH force, I've removed all of the bolts I thought I need to remove (in red) but nothing seems to be coming off. Im wondering if the screws for this center cover (i dont know the technical name) needs to come off too. The screws highlighted in yellow.

I've looked up the diagram on Bike Bandit but can't really tell if it's necessary to be removed.

3. I considered trying to "fish" the chain through (and not replacing the front sprocket) but i NEED to remove this because I need to check if I broke the clutch release assembly. http://www.thegsresources.com/_forum...d.php?t=175648



Thanks in advance generously patient members of GSR!

[Nessism]

You need to remove the center cover first.

[chuck hahn]

Take the ones in yellow off..remove the cover..then remove the other sprocket cover screw thats inside. Not the three that are holding the clutch actuator ...

[tkent02]

I am parting out a 550L. Do you want the centerstand?

[VariableValve]

So been working on trying to get those yellow screws out. Unfortunately I don't seem to have been the first one to try and extract these screws. The heads are badly worn and slipping with any screwdriver I used. I went out and bought a screw extractor, only to have it snap at the tip. Now the tip of the extractor is stuck in the screw head (it's too hard to drill out) and all three bolts are still in

This is becoming a very hopeless situation. Anyone have any idea how to remove screws like these?????

[Nessism]

First of all, do you have an impact driver? The type you hit with a hammer? This is a necessary tool when dealing with screws like that.

I'd take a dremmel tool with a small cut off wheel and cut a slot in the screw. Next, use a blade bit in your impact driver and knock the screws out. Worst case, you damage the cover which is cheap and easy to find.

Good luck and keep going...

[JEEPRUSTY]

do not use an extractor on bad screw heads
if you use a good drill bit of approxamately the same diameter as teh screws shaft then you cant pop the heads off by carefull drilling.

[VariableValve]

Thanks for your help everyone. I went and bought some PB Blaster (recommended from another forum), an impact driver, and cold chisel. I worked at it all day and I was able to get the screws out by using the cold chisel and actually hitting the screw heads at an angle and using that sheering motion to twist them out. Worked up quite a sweat, but I got those out and I'm at the next step.

How do I remove this screw? If I try to twist it it simply moves into the housing... I'm trying to use a wrench + screwdriver but I cant create enough torque to twist it out. Am I doing this correctly?



thanks again!

[Nessism]

Don't mess with that one, it's for the clutch adjustment. It's not holding the cover on.

[Redneck]

To mimic what Kent said and to top off that I am only about an hour north of you. I may also have an extra center stand you can have if you want. Drop me a PM.

Paul

[VariableValve]

Thanks everyone for the help. I took a bit of a break and ran into some other issues but I'm in the process of reassembly. I found a piece that I cannot figure where it came from.



It dropped out when I was removing the chain cover. Anyone know where this goes? I can't find it on any diagrams or schematics...

[mike_of_bbg]

That looks like the nut for the lower left motor mount. I recently lost mine and discovered this when the bolt was half sticking out after a ride. Bought a new one and installed with Blue Lock-tite.

Part # 21 here:

[mike_of_bbg]

Take the ones in yellow off..remove the cover..then remove the other sprocket cover screw thats inside. Not the three that are holding the clutch actuator ...

Am I missing something? I don't have to take the small cover off to remove my sprocket cover. I don't see an attachment screw under the cover on the fiche. The six red screws should be all that you need. On mine it's difficult (but possible) to remove the clutch cover without removing the peg and shift mechanism.

[VariableValve]

Thanks Mike, was from a different part of the bike than I thought!