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Author Topic: 1980 GS550E + 2000 Katana 750  (Read 2058 times)

Offline scott s

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1980 GS550E + 2000 Katana 750
« on: Feb 01, 2018, 08:35:11 »
 I picked up a 1980 GS550E for $100. Set about getting a title and making it legal and started ordering a few parts for the rebuild. I learned about combining the 550 engine with a 650 top end and, while reading on that, I found out about the GSX750F swap.

 There seems to be a few people who've done it but actual information is scarce. Screw it, guess I'll learn as I go! I found a more or less complete 2000 GSX750F (Katana for us in the States, Teapot to you guys in the UK) and snagged it. Here are the two donors.



1980 GS550E. Super oily engine, major wiring harness issues, etc. But I think it's a handsome bike. Or, could be.



 



 2000 GSX750F



Not running. Says the carbs and tank got dirty (and I see evidence of that) and he burned up the starter trying to get it to start. But the engine is clean, wiring harness doesn't seem hacked up, except for some of those hideous LED strips, and I have front and rear suspension I can play with.




Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #1 on: Feb 01, 2018, 08:39:40 »
The GS is already stripped down to a rolling chassis.







 I started stripping the 750 yesterday and should have the engine out today or tomorrow. I know there are two ways to get the 750 engine in the 550 frome; front mount or rear mount. My plan as of right now is to go with the rear mount method for better chain alignment and then use spigots up front to the the exhaust to fit.

 I'll also have to figure out how to get this oil cooler onto the 550 frame.






Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #2 on: Feb 01, 2018, 08:41:25 »
 The 750 is the model that has an electronic speedo, with a pick up on the sprocket cover. At the very least, I'll save the tach and speedo and come up with some new buckets or dash to hold them.




Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #3 on: Feb 01, 2018, 08:46:07 »
 I need to find out what this does. I mean, I know it's the Throttle Position Sensor, but what does it actually DO, other than sense throttle position? I was told that, technically, it's not necessary for my swap, but I am clueless about how it's used on the 750. What does it effect? Timing advance or anything?

 I also found that one of the vacuum ports on the carbs was open to the environment and the choke cable was fubar. Those things might have had a little something to do with his carb problems too, huh?




Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #4 on: Feb 01, 2018, 08:51:46 »
That's about it for now. 

 I had already ordered Sonic springs and emulator valves for the 550 forks before I learned of this swap. I think I'd be better off making the Teapot front end fit. Much better forks and brakes, even though the front brakes are dragging and the rear is inop at the moment.

 And I have to decide about the swingarm. It's steel, and I'm not sure if I want to go mono shock or duals.









 That also brings up the question of the controls. The rear brake and footpegs on the 550 should work, but I'm not sure about the shifter. I'm hoping I don't have to get into rear sets or GP style shifts.




Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #5 on: Feb 01, 2018, 12:53:52 »
Got the wiring harness out and the engine dropped. Just waiting on some more hands to help get the frame off the engine.




Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #6 on: Feb 02, 2018, 10:39:32 »
Finished stripping the frame and pulling the suspension this morning. 

 The LH clip on was bent and the upper triple clamp must have taken a whack at that time. The bolt snapped off when I tried to get it out. There are 4 big holes in the upper triple for the clip-on mount. I want to run handle bars anyway. 

 I know the Bandit 600 uses 41mm forks. Does anyone know if the Bandit triple and GSX-F triples are the same width, offset, etc? Can I get just the Bandit top triple or will I need the whole triple tree?

 Alternatively, any other top triple that fits the 750 and can be drilled for handle bar risers?

Online canyoncarver

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Re: 1980 GS550E + 2000 Katana 750
« Reply #7 on: Feb 02, 2018, 14:02:04 »
Sounds like you have quite a project with the motor swaps you are researching.  Looks like fun.
--

YZF750/1000R The Fly
KZ 750 Twin
ZRX 1100
KZ400 The Rabbit
65 Norton, My damn Shovelhead chop, and an 86' FXR
more YZF750R's, the KZ's, a Zephyr750...and the unfinished 75' CB550 cafe.
--

Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #8 on: Feb 08, 2018, 21:24:43 »
Bandit triple showed up. The Good News: It's the same offset as the Katana.

 The Bad News: Someone took a grinder/cut off wheel to the security studs on the ignition mount. Broken off bolts and ground down bosses. This is no good to me like this (unless I do a relocated ignition switch).




Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #9 on: Feb 08, 2018, 21:28:38 »
 Pulled the brakes out for a once over, since the fronts were dragging so bad the wheel would hardly move and the rear was inoperable.

 Fronts were just standard, dirty, dry, old crap. I could rebuild them but found two good used calipers for less than the cost of one rebuild kit.



 The rear? Whoo, boy. Someone had worn through the friction material, through the metal backing plate and started MELTING the piston by using it directly on the rotor!







 The P.O. had purchased a new Galfer rear disc and a set of pads. I found a good used rear caliper for $17 shipped. That oughta fix it.