'85 550ES (more rejuvenation than restoration)

[detorn]

with a lot of help from this forum and friends the fuel/air problems are solved. see links above for details. But now that I've got the bike going I realized it was a little too hard to stop. with that I bit the bullet and bought new SS brake lines from ren's auto parts. I also picked up a master cylinder rebuild kit just for good measure. Another problem I've been ignoring is a petcock that leaks when in the on position, I ordered a rebuild kit for that as well.

while I am waiting for those parts to arrive I need to sort out the turn signals. I may have gone too small with the ones I picked. it wouldn't be a problem if they were brighter, but they are quite dim. may try to find an oem set, may try to improve the ones I bought. not sure yet. suggestions welcome.

Above I mentioned that I swapped out all the screws on the carbs, here are a couple of pics of what that looks like.

bowls


gang bar, with bonus A/C left in yard for the last year now.




new spending:
SS brake lines - $113.
Master cylinder kit - $38
Petcock rebuild kit - $27

new total - $1898

[GateKeeper]

Making some good progress on this build.....

the petcock rebuild kit, will probably do you no good, you would have been better off getting a new one, most of the rebuild kits don't work....unfortunately, or so it is written here many times over...

now you just need to paint the rims black, polish the lip,,,,and your bike will look similar to mine...LOL

Cheers

[skreemer]

BTW if you lose the air/mix screws or springs, they are the same as on the late 80's early 90's GS500E models. (yes the parallel twin bike)

[detorn]

BTW if you lose the air/mix screws or springs, they are the same as on the late 80's early 90's GS500E models. (yes the parallel twin bike)

good to know, I may pick up a couple just to have the extras

[detorn]

oh the horror...

So the brake haven't been right and I've been going step by step to try and get them firm again.

I ordered some goodies...





while fighting to get the lines and horn snugged to the stem I had a little accident.




couldn't get at it without taking the front back off and then this happened...



if you're wondering when I really stopped caring about appearance, this is going to be the moment... that paint just ripped right off. oh well, there are bigger issues any way.

these soda cases I was using to hold up the calipers are what gauged the paint..





so anyway. the brake lines I got from ren weren't perfect, but dude got in touch with me unsolicited and said he wants to fix it and send me a new one... good on him. that's the kind of service you like to see. I have the wonky one on there now, its passible.

moving on. the tool I was using to get that severed bolt out broke off in the opening. so now it can't even be drilled out. that opening is where the T in the brake lines and the horn mount. now there are just being held by the one opening left. maybe just replace the whole piece when I get a chance.

anywho. lines on, bled brakes, still no love. today I took the calipers off again and double checked them, cleaned them again, yada yada. bled yet again. it was better, but still not right. Only thing left is the master cylinder. However it seems that I bought the wrong master cylinder rebuild kit...lol duanage said he may have a MC that fit that kit and my bike.. still waiting to hear for sure.

Took the bike out for a quick shake out. felt good but ran super hot. probably not an issues, but keeping an eye on it.

I'm looking at threads where people spent as much as I did and have really high end restores, yet I can't even brake..lol

gotta figure out how I keep making mistakes

more to come

[BigD_83]

What was wrong with the first set of brake lines that they were not perfect?

[BigD_83]

What was wrong with the first set of brake lines that they were not perfect?

Just bumping to get this question out there again. I'm going with new brake lines from Raymond again, this time for the 650 AND the 550 (did a Honda Rebel before) and now that I know you'e gone through this with him, just wondering what the problem was.

Question 2...the valve cover fitment is really tight to the frame. Is it possible to get it out without removing the coils and every other little bit hanging around the frame, over the valve cover?

[spyug]

and now that I know you'e gone through this with him, just wondering what the problem was.

Sadly, I think I'm seeing a trend here. A month or so back, Gatekeeper and I ordered 2 sets for our FZ750s and they were quite a bit off in size and banjo position. I had sent him the full set of stock lines to measure and compare fittings and they came back with one front line (from the junction block) on the right side being too long by about 1" and both banjos crimped at the wrong angles. The back line was also overlong with an incorrectly angled banjo. I did manage to get them on but they look like snot.

Unfortunately and despite being a former multi purchase customer, Raymond refused to do anything other than offer to give us back our money. No offer to make it right.

I am still not happy and doubt that I'll buy from him again. Shame really, as I had previously thought very highly of him and boosted him here and on other sites.

Good luck with your order.

[boingk]

Pretty much why I don't trust custom work, I can wreck my own parts without having to pay someone else to do it for me.

Good work on the bike so far, and don't bash 64hp - the original CB750 only had a theoretical 67hp, weighed a lot more, handled a lot worse... And was touted as a superbike!

Once she is up and running properly you'll really enjoy her.

One tip for procedural work, read through what you have to do and familiarise yourself with the parts involved. Never over torque parts and always proceed carefully and thoughtfully. Mistakes do happen, but its what you do to prevent repeating them that counts.

Cheers - boingk

[detorn]

An update:

So I went quite for a while but the project has not died. I ran out of weather last year with the bike still not really running and it sat through the winter.

Though covered with a tarp it took a beating (next year I will have to shell out for a storage unit). Thankfully after getting some fuel, a battery charge, and putting some Duaneage on it, it came back to life. We cleaned or replaced a handful of electrical connection, new head light, clutch and choke adjustments, and some general tidying up I took it out.

After being on the road for two+ hours and heading home, the bike died. the same problem I was having when I put it away. Today I mounted a new to me Honda R/R courtesy of Duaneage, and I'm going to assume that is the last piece of the puzzle.

Tuesday I take it in for inspection with realistic hopes that it will pass.

So here is the list of all of the parts/work thats been done to this basket case of a motorcycle.

Sprockets
chain
tires
brake pads
calipers
brake lines
master cylinder
brake switch
petcock
fuel and vacuum tubes
gas tank
mirrors
choke cable
choke nuts
throttle cable
regulator/rectifier
battery
fuse box
stator w/cover
fork seals and o-rings
carb o-rings and gaskets
intake boots and clamps
turn signals
head light gasket
head light bulb
triple tree
gas cap
fuel gauge float
oil filter
coils w/leads, caps, plugs

and I'm sure I'm missing some stuff. On the still left to do front I've got:

turn signals (would like to find originals when I have the loot)
body work (the paint job I did was never that good and got worse over the winter)
cleaning (once again exposed to the elements too long, surface rust)
paint pipes, engine, carbs
check clearances
verify oil coolant system
install triple tree (I stripped the hole that holds the horn, I have the replacement tree, but its a big job
possibly rewire completely (I'm really not happy with how the wiring is done on this thing, if you've done major wiring upgrades let me hear about it)
LED turn signals (if oem doesn't happen)


thanks to everyone who helped

[uscrosser]

You had to post the cheese steak pics ?

I transplanted from Philly in 2006 (with my 82 GS1100e in my van).

Scanning through this post the cheese steaks caught me unaware.
I was not prepared for the sight!

Can you send me one? Fried onions, mushroom, hot & sweets?

PLEASE .............

Excuse me.......I need a moment

[SVSooke]

Parts N' More has repro K&S sigs in this
http://www.partsnmore.com/parts/suzuki/gs550/?filters[fitting]=custom heading,about 1/2 way down.The rubber bit on them degrade over time and UV so good luck finding good used ones.Found out my local dealer up here could get them to so I would check locally first.

[detorn]

I transplanted from Philly in 2006 (with my 82 GS1100e in my van).

Scanning through this post the cheese steaks caught me unaware.
I was not prepared for the sight!

Can you send me one? Fried onions, mushroom, hot & sweets?

PLEASE .............

Excuse me.......I need a moment

I'd give up the cheese steaks for your weather in a second

[detorn]

Still not right...

Two major problems are the bike is over heating like crazy. To the point the tank is getting warm. And being able to start it using the start button is hit and miss.

Friday the valves were checked and adjusted. On the way home the bike stalled like it was out of gas. I pulled over and tried to start it and got nothing. hitting the butting did nothing. I set the petcock to prime and sat for a half hour on the highway in the rain and was eventually able to bump start it to get home.

The next day it started right up. I went out and rode for an hour. I stopped for a soda and again the start button did nothing. no attempt to turn over, no dimming gauges. nada.

Again I sat. after a while I was able to bump it and got it to duanage's house. we swapped in some new leads to the battery. move the sense wire from the brake light to the battery. cleaned the solenoid, and charged the battery. It came right up when it was time to leave.

Next day, same problem. push button, nothing. wait. push button, nothing. bump start it, comes right up.

Charging system seems to be good. battery I think is okay, it is less than a year old. Has a replacement stator and honda regulator. new, after market coils. ideas welcome.

as far as the heat issue I ordered new stock jets. Lean jets were put in earlier to prevent what looked like a rich condition, now it looks lean. I am hoping the stock jets and leaving the petcock on prime will solve and stalling and heat problems.

[recycled64]

550 parts

Unsure if this helps, but this guy has a TON of Suzuki parts, some 550 stuff-

http://stores.ebay.com/Mr-Cs-Motorcycles/suzuki-/_i.html?rt=nc&_fsub=17666854&_sc=1&_sid=322193286&_sop=10&_trksid=p4634.c0.m14.l1581&_pgn=2

And these-

http://www.ebay.com/itm/1980-Suzuki-GS550ES-GS-550-ES-S399-rear-turn-signals-blinkers-winkers-set-/291170747905?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item43cb210601

(I think he's wrong on the year of the bike he took the parts off, though)