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1978 GS550 Custom Build Project

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    #1

    1978 GS550 Custom Build Project

    Hello All. I've been lurking on TheGSResources for years now. Thanks for all the wonderful insights over the years. I've owned my 1978 GS550 since Spring of 2015. In November of 2016 I decided to tear it down, rebuild the top end and rebuild it custom as a cafe racer. I have documented the entire thing in a video documentary series on YouTube in case any of you are interested. The focus has been to show the detail that is needed for a novice to do this work on their own bike. I've learned some things about making videos along the way and quality improves over time. I hope some of you enjoy.

    Episode 1. Tear down.

    Tear Down - Suzuki GS550 Cafe Racer Build (Part 1)
    https://www.youtube.com/watch?v=ctahoyrDgXw&list=PL2518uxZnBT0MDB8WSc5JxHmS80qZFmaj&index=2&t=0s
    The Urban Monk begins tear down of his 1978 Suzuki GS550. This is the first in a series of ongoing videos detailing a custom build of a cafe racer. FargoMonk...
    Last edited by Guest; 03-04-2019, 08:19 PM.
    Tags: tear down
    #2
    Episode 2. Continue with tear down.

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      #3
      Episode 3. Engine removal.

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        #4
        Episode 4. Removing the tappet cover, gathering tappet clearances, removing the cam chain tensioner, checking cylinder compression and removing the cams.
        Last edited by Guest; 03-04-2019, 06:13 PM.

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          #5
          Episode 5. Remove cylinder bank, inspecting camshafts, checking them against service limits, and removing stubborn screws from the intake boots.
          Last edited by Guest; 03-04-2019, 06:13 PM.

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            #6
            Episode 6. Remove the cylinder bank and determinewhether he needs to bore for oversized pistons or can stick with standard size.

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              #7
              Episode 7. Removing pistons from connecting rods.

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                #8
                Episode 8. Stator, clutch and starter cover removal.

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                  #9
                  Episode 9. Remove starter, ignition points, advance and measuring clutch disks.

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                    #10
                    Episode 10. Cleaning up the engine. Rust removal. Stripping clear coat.

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                      #11
                      Episode 11. Replace oil filter cover stud. Prep engine for painting. Inspect transmission gears and dogs.

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                        #12
                        Episode 12. Painting engine.

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                          #13
                          Episode 13. Clean pistons.

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                            #14
                            Episode 14. Install new piston rings. Install pistons. Hone cylinders.

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                              #15
                              Episode 15. Painting cylinder bank and installing.

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