1982 GS 550 M rolling resto/customization

[Guest]

Hi all!

I managed to buy my first bike, and I happy to find this forum aswell I bouth this baby for a bargain price, sadly it is in a vary sad condition right now. In Hungary these are rare bikes, it's hard to find parts, but I felt in love with the GS's classic look, and I wanted a project bike, so I could not leave it to destroy by the no money barbarian "fixes". Sadly she's got a hard time under the previous owner's.

Some picture from 2012 january from the moment of buy:

[gabos666]

TO-DO list

My dream is to bring her back from the ashes, where the previous owners left them. I'm very angry, because they spent no money, just use it, so there are plenty things to do.
The goal of the project is to make the bike a reliable, classic looking bike, with some upgrades in the electrical system, suspension, and brakes. I have got no garage, nor tools right now. So I have to do it in the street, and sometimes in the company's yard, where I work. It's my first project, more or less for learn and for fun. The budget is low, so don't expect fast progress.

OK,so fault list first round:

-smoke from the exhaust system
-scooter mirror in the left side
-scooter turn signals all around (what a barbarian work! drilling's are awful, and looks very nasty)
- turn signal relay from an east german MZ, the signal rating is way off because the smaller turn signals
-electrical mess around the battery compartment, again barbarian hordes attacking
-dents either side of the tank
-rust and mess everywhere, they never clean it
-trash tires
-trash painting I think it was some 5 minutes ratle can painting
-right hand bar control switch is shot, they cut off the emergency stop button
-left hand side bar control switch, the high beam button runs hard
-engine side covers emblems are gone, and looks very sad
-not OEM exhaust system it is very loud, and doesn't sounds good, the police will catch me for it
-tacho cable is missing
-beveled drill for the licence plate (I know Conan again)
-DIY ugly seat cover

Huhh for the moment, that's all. That's enoguh for round one? I think so.

[gabos666]

Round one

I bouth it in january, i bring her for a very good mechanic to fix the engine smoke, and to change the tires. Right now, i still waiting to get the bike back. Very slow progress from the guy, but I know the engine will be flawless, and that's the point. I want to do the rest myself, so I'm glad to find the forum, andBikeCliff's Website is absolutely superb.

The smoke comes from the cylinder oil rings, and because the wear of the plunger simmerings.
Nothing horror there, just 30 year's war against the elements. Huh, I'm very happy about that. New gaskets, valve clearances will be set, new spark plugs, fresh oil, carburetor setup.

I will keep you guys informed from the progress.

[DannyMotor]

Youre not keeping that exhaust are you?? Hahah. Sounds like youre well under way!

[gabos666]

Youre not keeping that exhaust are you?? Hahah. Sounds like youre well under way!

For now, I keeping it, because the money. I bouth the bike for about 690 USD, and a good 4-2 exhaust system is way above my budget these times. I will put some sound deadening for temporary fix, because the police will hurt me badly for the loudness. And it sounds like trash, just roaring louder as the rpm goes up, you can't tell from the sound wich rpm zone are you. So it have to go, but not now It's impossible to hunt down a used OEM exhaust system here. From ebay the shipping cost will be high, so I have to wait, and put some money into it. There are many problems what I want to fix prior than that.

The light is too far now, but I just began the project, so I'am hopeful.

[Mista M]

welcome, sounds like a nice project. You may want to also check out http://forum.oldskoolsuzuki.info/cgi...ct=discussions in the for sale section. They would be much closer to you than for shipping. Bike doesn't look too bad from the pictures. Hope you have it worked out soon.

[Nessism]

Good luck with your project! The GS gods will smile on you for taking on this project to bring the bike back from the dark side.

You might be able to make some new baffles for those mufflers. Better than getting busted by the cops.

[gabos666]

Messing around

Sorry guys, but nothing interesting from the bike itself. The machanic still didn't put together the engine

But, I managed to buy some interesting things:

-Clymer manual
-rigtht hand side bar control switch (not exactly the same, but close enough to the original one, and much better looking)
-Kawasaki ZX10R regulator/rectifier for really cheap money!
-OEM tacho cable

[gabos666]

GS 550M with bigger kat head

Just found this 550M in Hungary's biggest used cars site:

http://www.hasznaltauto.hu/motor/suzuki/suzuki_gs_550_m-5709099

Hehe! It's got the biggest katana's head!! Nice!!! I think i have to buy one myself, too.

[gabos666]

NEWS!

Finally she is came back!! And she is alive!

I am very happy right now!! Strong engie, good suspension, very fun to ride this 30 year old bike!!!

Bad side:
-I almost forget the nasty mad max look
-smoke!! I wrote it in the engine topic, maybe just some time needed for the new rings to broke in...
-today it refused to start, battery was empty


So first thing: electrical playground

I put the battery to charge, meanwhile I try to identify the cables who play with who, and where everything goes. I am pritty happy, more or less I could find out the basic layout. I used the Clymers manual as a reference, but there was some difference, because the PO's hecking.

Some picture from the present days, WARNING lot of image!!!

[gabos666]

[gabos666]

I was shocked, because the bike refused to start yesterday morning. I borrowed a battery charger, and charged the battery about 5 hours. Today morning there was no problem. Run like a charm.
I was concerned about the battery, and the charging system so I opened the Clymer manual, and do some test.

1./ battery didn't go under 10V under starting, so the battery is enough for a short period, 10,8V under cranking
2./BUT there was no charge!!! 12,8V without load on battery, and 12,5V with ignition on, and 12,2 with high beam, didn't go higher as i pull the throtthle

OK no panic!!! Alternator test without load... about 80V AC as should be....oh thanks god, the problem is not the alternator!!!

Let's check the connection between the reg/rec unit, and the alternator.

Some cleaning, and thanks to god, there was some light in the darkness!!

But, the reading was not sufficient enough: 13,6 V at 5000 rpm.

I think the connection is faulty between the reg/rec and the alternator, I have to double check the battery, and I suspicious about the reg/rec unit is faulty too.

So the time has come, when the MOSFET Shindengen FH-010BA unit after a long waiting, can do it's job once again

So my plan is the following:

-new reg/rec unit with direct connection to the battery, without the hassle with the handlebar control
-new fuse box with newer type fuses
-new connectors, and I think I will completely rebuild the wiring harness with fresh cables

[gabos666]

OK, there is a change in the story. This is not going to be a rolling restoration anymore. At least, that is the plan. I was so stupid to think, I can do this bit by bit. A can see now, every bit need some check and love. There is just one way to do this. I have to dismantle completely the whole bike. Do once, do it right.

I have no garage or a normal place, where I can work during the winter. I pull the carbs out, because the overheating, but they just have to wait. The baby kat may need to do the trip whit her own legs to the garage. So first thing is to find a garage. Hard project in Budapest (capital of Hungary). Fingers crossed, wish me luck.

A new project order:

-find a garage(near my rental,low cost,with electricity, I can only dream about a heated place, at least not in my budget category)

1./Complete tear down
2./make ready the frame to powder coating
3./repaint and polish the rims
4./new footpegs to rear and front
5./exhaust need new, or used OEM
6./rewiring the harness with improwed parts
7./side panel fabrication
8./replace the HONDA tail light, with a SUZUKI one
9./ new seat cover
10./ remove the dent from the tank
11./painting
etc. etc.

Some picture finally from the carbs:

[GateKeeper]

did you not get your welcome package ? if yes sorry, if no here it is, you can get lots of manuals and such from the site, and lots of tips and tricks , trouble shooting and so on...

Greetings and Salutations,

I have not been able to be on the forum much lately and many new members have not received their "mega-welcome". If you are here you probably have a 30 year old motorcycle that needs about 20 years worth of maintenance. You'll find all kinds of helpful tips, procedures, manuals, etc, in the links below. Let's get started.

Let me dump a TON of information on you and share some GS lovin'.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. This is what NOT to do: Top 10 Newbie Mistakes. Now let me roll out the welcome mat for you...



Please Click Here For Your Mega-Welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[gabos666]

Thank you!

I am allready read these when I found this superb forum! This site is top, I have never seen better! I am sure, I can find here answers for my questions.