79 GS550E Barn Rescue - Suggestions wanted

[Guest]

Hello, I am new to the forum and new to the GS in general. I acquired the motorcycle from a friend for $200. It has been sitting in a barn for 10 years and then out in the weather for the last 2 years. It is mostly complete other than goats getting to the seat and the wiring harness. It only has 15,000 miles on the engine/trans and the engine does not seem to be seized (I tried the kickstarter). With the bike on the center stand and clutch lever pulled, I cannot seem to get the shift lever to move in either direction. I was hoping to completely disassemble and do a frame up restore but want to make sure that the motor/trans is going to be reliable. I am open to suggestions on where to get started on this project. I have some mechanical experience with cars and have rebuilt a couple lawnmower engines (I know this is going to be much more work).

My initial plan is to try to get the thing started by replacing the battery as well as a couple of the spark plug wires in addition to rebuilding the carbs and cleaning the tank and lines. Does anyone have tips to starting the engine for the first time after 12 years of sitting?

[ev0k1ll3r]

Another thought:this thing has been neglected for so long and really needs a lot of work. What are your thoughts on commencing tear down right away and compile a shopping list as I go? I intend to replace anything and everything that is necessary. My goal is to build a very reliable motorcycle with a total budget of $1500 and no specified timeline.

[78550GS]

Set it back down on the wheels and rock it back and forth to try to shift it?

I wouldn't start it right away until the oil is fresh. Might help with the gears too.

I picked up a 78 550 last year that I now have less than 1200 in it and I ride every day. Mine wasn't neglected as long though.

[nejeff]

Put it back in the barn. Use or sell it for parts and get a better platform. For $400-$500 you can probably get a runner with wiring and seat intact and that puts you well ahead of where you are. Destroyed wiring can be a real PITA and I have seen it sidetrack MANY projects

[mmattockx]

I intend to replace anything and everything that is necessary.

My goal is to build a very reliable motorcycle with a total budget of $1500

These two statements are completely at odds with one another. Just the very obvious parts will ring up close to $1000 worth of bills:

Tires
Brake pads
Rebuild brake calipers and master cylinders, replacing parts as necessary
Brake lines
Chain and sprockets
Rebuild carbs
Battery
Wiring harness
Seat foam and cover
Fork springs, seals and oil
Shocks


If there is anything significant lurking inside the cases or other chassis stuff needing attention you will blow your budget very quickly. If you want a project to rebuild, then it's fine. If you want something to actually ride in less than a decade then you should probably find something that is at least running to start with.


Mark

[one_civic]

Put it back in the barn. Use or sell it for parts and get a better platform.

You will be b better off finding a running bike and using that one as a parts bike

[eil]

Post some pics of that bike and its goat-eaten seat if you get a chance.

So far, based on your description, many of the replies have said that this bike is not worth saving. Well, they're right if all you're looking for is a decent rider. $1500 is definitely on the low end of what you will spend making this one road-worthy again. However, I think this would be a fine platform if you're very interested in learning how to work on motorcycles and don't mind fixing absolutely everything that's currently wrong with it. (And there is always more wrong with it than you can see right now.)

I bought my 850GL two years ago as a non-runner and put waaay more money into it than it will ever be worth. And it still looks like crap. But I don't mind, I consider it the cost of an education. But it runs great now and is an absolute blast to ride.

Welcome!

[ev0k1ll3r]

Thanks for the replies. I suppose my budget is pretty unrealistic. At the moment that's what I have to start with. I see the point in getting a running motorcycle and starting with that but, I am still interested in taking this on. I am confident that I can figure out most of the work to be done on this bike using the FSM and you guys as a guide.

[chuck hahn]

New cables for the clutch and throttle also. I say for around 2G youll be riding one heck of a good bike. Now understand this..that means a full tear down and rebuild of the brake master cylinders, he brake calipers, carbs, intake boots and rings, tires, oil and filter, valve adjustment, clutch inspection, and the new associated gaskets.

Rebuild the carbs and do the valves first off. Then get a wiring harness off of Ebay and swap that out. Get it running and get the brake systems squared away. seat are all over ebay and you can place parts wanted adds in that section as you go.

[chuck hahn]

Heres a harness for cheap. Just number each side of every connector as you undo them..1/1..2/2..and so on till you have the old one all numbered and undone. Install the other one and plug everything back into its mating connector.

Clean the replacement one up with some Fantastik and rags and it will look pretty decent.

http://www.ebay.com/itm/1979-SUZUKI-GS550-GS-550-WIRING-HARNESS-650-750-/350273198585?pt=Motorcycles_Parts_Accessories&hash=item518de8d9f9&vxp=mtr

[chuck hahn]

Lots of seats listed too.

http://www.ebay.com/sch/i.html?_from=R40&_trksid=p2047675.m570.l1313.TR12.TRC2.A0.H0.XGS+550+seat.TRS0&_nkw=GS+550+seat&_sacat=0

[chuck hahn]

As for what to do from its 12 years of sitting. Put a good dose of a 50/50 mixture of Acetone and any brand ATF into each cylinder and let it sit a few days. It will free the rings up in the grooves. Be mindful that its gonna smoke like a wood stove chimney when you fire it off, so do that outside. Get it running with some house fans on high in front of the engine and let the stuff burn out of the cylinders......may take 15 minutes or so.

May also be best to drain the oil and put new oil in before initial restart. Dont worry so much about the filter as to the oil at least not being full of water condensation from sitting...all that will be in the pan.

[bomber737]

Chuck is one of those guys you should listen to.
That being said, My bike sat for 28 Years in a shed and 7 months outside. All I did was marvel mystery oil in the cylinders, let it sit. A week of this and I turned it over with plugs out to pump excess out, put plugs back in and fired it up. I put fresh oil in the thing before I fired it up mind you. Been fine since and does not burn any oil.

[ev0k1ll3r]

wow! thanks so much for all the help chuck. Is there any way to replace spark plug wires and caps without having to replace the coils as well? If not, that's okay since I was thinking to upgrade/replace to green coils. 2 out of 4 wires are pretty chewed up and the one is completely broken in the middle of the wire.

[chuck hahn]

Yes..use the search feature and use key words like replacing coil wire etc etc. But the way I do them is to use the bench grinder and grind away then plastic hump the wire goes down..go easy and just get to the wire and go to the end where the wire sticks onto the spike. ( theres a spike in there the end of the wire makes connection with ).

Then use 5 minute epoxy to glue in the new wire ( its a 7MM plug wire by the way). Then I use some more epoxy to rebuild the housings case shape. Plastic body filler works great too. I have always had trouble getting the new wire stuffed into the hole following the tutorials..so i cheat.

Someone once posted pics of some sort of adapter that you use to connect a short section of the wire comming out of the coil to a new wire running down to the plug, but I cant remember who made them or their technical name.