1982 GS 550 M rolling resto/customization

[gabos666]

OK, some full body shot:

[gabos666]

I saw this, and I want to ask if this is OK, from a rebuilded enngine, I rode it only 400-500 kms. This is OK IF this is like a coal mine? Head was down and the pistons was refreshed, so this is because the overheating,right? Should I open the head?

[gabos666]

Back section again, some loss of paint, and a nasty hidden fault in the brake!!

[gabos666]

The garage slowly full of parts

[gabos666]

Electricity monster again:







Oh yeah one of mine stator wires was off, and the second one half way down...real good...

[gabos666]

I think these were upside down, right? Theye are hard, I think I should change them all:

[gabos666]

And some gunk and oili mess to the end:

[gabos666]

Engine out

Guess what happend last night?

[gabos666]

bare frame

Hi all!

I have little time to work on my little katana, but the frame is slowly done. I want to powder coat the frame, but my concern is the little frame ID plate on the front. I am not sure how the paint will look like. I have to keep it untouched!

The post for it:

http://www.thegsresources.com/_forum/showthread.php?t=205129

[eil]

Looks like you're off to a great start. I can tell I'm going to enjoy following this rebuild. I'm working on my first bike as well, although it will not be a frame-off restoration like yours.

[gabos666]

bearings

Thank you eil! I didn't want a full tear down resoration either, but I soon reailzed that, cutting corners will revenge themselfs later on. So, I took a deep breath and teard it down completely. I can trust my GS only that way, if I am sure everything is fine inside and outside. It is lot of time and money, neither one is plenty right now. But I want a real trust worthy superb GS. Forexample if I didn't tear down the swingarm, I never saw this:



And if I didn't touch the suspension, I never see this:

[gabos666]

bearings02

So after the bigger components are out, the only things I have to take care are bearing races, bearings, and little rubber grommets. They are have to come out before the powder coating. So preparation tho the fight begins:
This little thingies should come in handy:



And the big star of this horror movie:


I tried to kick out the head bearing races with some washers and threaded rods. What a nightmare. Neither one move!!! With some persuation one swingarm bearing just fly out! But the other one didn't move. The reality is I completly destroyed the rotten bearing, because I have to use some real heavy blows.



I am stucked right now. I will try some heat treatment, but I don't want to hurt something with the torch. I was absolutely sure about this will be hard work, but I don't expect this level of s***ing!!! I don't give up!!

[gabos666]

bearing03

The rear and front suspension is nearly completely in parts. Bearings are out, they where in a preatty good nick.





I can't drop down the front disks, but I found this:


Somebody drilled out 2 of the disks hole to bigger thread:

[gabos666]

plans

So just sum up my plans for the near future:

-I will try to done with the bearings
-prepare parts for sand blasting and powder coating:

frame(cover holes,threaded holes, etc.)
swingarm(cover holes)
tripple trees (same, and bearing removal!!!)
airbox (tear down electic parts, etc.)
side and center stand
footpegs
another small parts (ears etc)
downpipes to black chroming

I am not sure If I want to PC the wheels.....

I have got a resonable price quotation for this, so every bit I can PC, it will be PCd. I just absolutely have to be sure, they know their jobs, because there are spots, where sand and powder coat is not welcome.

[Dougpod]

Great job so far! Looks like you're well on the way to having a really nice Kat. Keep it up!