1980 GS550 project

[ChicagoBob]

This 550 is coming along pretty well. The idea was to reduce weight, especially all that iron around the headstock (instrument and headlight mounts, ignition, etc), and to improve handling. To those ends, I bobbed the frame and front fender, upgraded the electrical system with a Shorai battery, modern rectifier (in a custom aluminum battery box, which is tons lighter than the stock steel one), and a relay for the coils. I also replaced the instruments, headlight, and turn signals, fabricated the associated mounting hardware from aluminum, and relocated the ignition switch under the seat. I used a lighter seat, Tarozzi clip-ons and Slipstream Cycle Works rearsets on handmade aluminum brackets.

13.5" rear shocks and a 1" dropped fork quicken the steering without affecting stability, and encourage use of the additional ground clearance provided by the rearsets. The engine is stock, and runs well. Since Suzuki supplied decent swing arm and headstock bearings, no attention was required in those areas.

Overall, it's a really nice cafe-style bike that weighs nearly 60lbs less than a stocker.

 

[steve murdoch]

60lbs is significant. Well done.
Did you just slide the fork legs up into the trees?
I had never heard of the Slipstream stuff. Nice looking products with good sale pricing.
Which one are you using? https://slipstreamcycle.com/t/rearsets

 

[ChicagoBob]

Yes, just slid the forks up. I used the CB350 Four rearset kit. I drilled the Suzuki shift lever for the kit's Heim joint. On the brake side, I had to modify the Suzuki brake lever and shorten the connecting rod, because the Honda brake lever is a different pattern than Suzuki's. Also, the connecting rods are not the ideal length for the Suzuki, but they work.

The footpeg mounts are made from 1/2" aluminum and mount to the bike's original footpeg bolt holes.

Tarozzi makes a nice rearset kit that bolts right on the GS550, but it costs more than $300 and isn't available until October, due to the factory's summer break.

 

[scratch]

Gotta say, love that you went about this without molesting your stock airbox :clap:.... the black covers with red tank look great and dig the L front fender cut down!

If you are going to keep the bike on a diet past this point, a 4-into-1 exhaust shaves a good deal of weight and jetting changes to match are not radical.
If you want to keep the balance look of the chrome pipes on two sides, the chrome MAC 4-into-2 exhaust is also much lighter than stock.
Ideas for next season... riding season is now.