'81 GS550 Cafe Build

[Sci85]

I might be missing something here but I don't see the tool, could you please redirect or spell it out to me because I am wrestling with that issue at the moment and all help is appreciated!

Sorry, I've been travelling and haven't been on the site in a bit.

The tool is just over half way down the thread page. It's basically using the rear engine bolt with a big washer on it. Follow the link then scroll down the page and you will find it.

Sci85

[D-Mac]

Between work and personal stuff it’s been really hard to get back to this project lately. It feels good to be back in the shop!

To do it right, I decided to pull the top-end again. This time I decided to remove it before trying to wrestle the engine from the frame.
After removing more bits than I can remember, I got the cams and head off easily enough. Here are some pics showing what I believe to be a twisted crankshaft. Pistons 1&2 are off.

Timing mark for pistons in cylinders 1&4 lined up. Both pistons should be at TDC at this point.


Here is Piston 4 – right at TDC on the mark. Good.


Not so for Piston 1! It’s already on the way back down when the mark is lined up. If you compare the two photos above, you’ll see what I mean. Here’s Piston 1 with the mark lined up. Ugh.


Then I set the timing mark for pistons 2&3. Piston #3 is at TDC as it should be (2 pics)




Not so for Piston #2! It’s not as far off the mark as #1, but it’s still bad. Here are 2 pics.




Photo across the cylinders. Note the difference in height of Pistons 2&3.


The next steps are to get the pistons off, pull the engine out and into my stand, and start disassembling the cases. If I can find time to get that done over the next week, I’ll be happy. Then I’ll have to order the rest of the seals, fasteners, etc. and wait 3-4 weeks to get ‘em all. Only then can I start what I hope will be final assembly!

The head gasket looks good, but I’ll be replacing it anyway. Ditto with the base gasket and various o-rings that have been compressed.

[psyguy]

Ouch!

But at least now you've confirmed the culprit

[headsbikesmopars]

Filters

Tell us about those K&N filters . Dual filters I think they are called. Where did you find those and what K&N part number are they. I like the look and it looks like they fit nice. Please advise and thanks. Its what I need on my GS550 .

[JvZ]

SUZUKI GS550 Katana 1982 K&N Universal Clamp-On Filter RC-2382

Been eyeing them out myself but also thinking of some stacks

[Sci85]

How are things progressing D-Mac? After the engine fiasco, hopefully you haven't lost the motivation to finish her up...

[Par6]

Just spent 2 hours reading this thread and it ends like this ?
It's like someone ripped the last page from a novel
Come on D Mac what happened ? Hope you didn't sell on the bay as an unfinished project

[JvZ]

Agreed, this was a huge inspiration for me. Dying to see e finished product

[ndimitri48]

Just read through this build GREAT JOB! I bought my 1980 GS550E last month as my first bike and have been working on it since.

[claygs750e]

Was the front end of the bike lowered? I see the forks look pushed through the triple trees enough so the clipons can attach? I'm thinking of doing the same.

[tigerfan474]

Tell us about those K&N filters . Dual filters I think they are called. Where did you find those and what K&N part number are they. I like the look and it looks like they fit nice. Please advise and thanks. Its what I need on my GS550 .

I believe they are #r2222 I have a set I'm looking to sell. Never used $50

[callahanoffroad]

Any update on this? Just read all 33 pages!