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Author Topic: 1980 GS550E + 2000 Katana 750  (Read 1042 times)

Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #10 on: Feb 12, 2018, 16:38:01 »
 Tried stripping the old paint off the lips using lacquer thinner and a Skotch Brite pad but, whatever it was, it was tough. But it was no match for Klean Strip paint stripper!



Before:





 After:





 I'll keep working on the lips and polish them up, then I'll repaint the centers

Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #11 on: Mar 08, 2018, 17:05:01 »
Slow going on this one, but getting some research done and making baby steps.



 Rick at OldSkoolCarbs took care of the  '95 GSX-F carbs for me. He found a few bent and rotten choke parts and will also assist with jetting for the pods when the time comes (this build, with the GS550 frame, doesn't allow for the stock air box and these carbs are supposed to play better with pods than the '00 models). I plan on using the K&N dual intake filters. I believe that RU-2922 is the part I need.










Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #12 on: Mar 08, 2018, 17:13:10 »
Also figured out the front end/triple tree. The 1980 GS550 used tapered bearings and the 2000 GSX-F uses caged bearings. I used the GSX 750 lower triple, a top triple from a same year 600, and bar risers from a Bandit 600. My Dad did a little grinding and modifying, and I ordered new tapered bearings from AllBalls, and now I have a '00 front end, forks, wheel and brakes on an '80 GS550 and still retain the handlebars. Ignore the tall bars....they're just for mock up and pushing it around the garage.









 Next up is to rebuild the forks and brakes and do a little detailing. We also have a pretty good plan on getting the Katana swingarm to fit.

Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #13 on: Mar 26, 2018, 15:36:15 »
 Found a set of clevis mounts for about $20 shipped. That will make going to dual shocks so easy. Hope to work on getting the swing arm fitted next week.




Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #14 on: Mar 26, 2018, 15:41:02 »
 I was leaning towards keeping the outward appearance "old school", but I found this Yoshimura slip on and was able to get it for $130 to my door. It's a $400 pipe and the dyno graphs show (presumably) big increases over stock. I figured that, along with the pods, jetting and some dyno tuning and I ought to be able to get to 100HP vs. the 94HP Suzuki claimed. And it would probably be easier to tune for this pipe vs. some cobbled together system. 

 No matter, it ought to be a good bit more than the 49HP that the GS550 was rated!






Offline LightsOut

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Re: 1980 GS550E + 2000 Katana 750
« Reply #15 on: Mar 28, 2018, 12:26:48 »
Cool build, following along! Bulding on a '82 GS550 Katana myself, so somewhere in between your bikes :) The 750 engine should give quite a bit more oomph. Man, that 750 was reallt badly neglected with those brakes and carbs... nice of you to give at least parts of it more love.

Perhaps I'm being stupid... but those clevis mounts are steel right? And the 2000 Katana swinger aluminium?

Offline doc_rot

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  • Oh the usual... I bowl, I drive around...
Re: 1980 GS550E + 2000 Katana 750
« Reply #16 on: Mar 28, 2018, 16:23:27 »
Following along. this is gonna be wild. what are your plans for stiffening the frame?

Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #17 on: Apr 03, 2018, 06:10:45 »
Cool build, following along! Bulding on a '82 GS550 Katana myself, so somewhere in between your bikes :) The 750 engine should give quite a bit more oomph. Man, that 750 was reallt badly neglected with those brakes and carbs... nice of you to give at least parts of it more love.

Perhaps I'm being stupid... but those clevis mounts are steel right? And the 2000 Katana swinger aluminium?

 The GSXR swingarm is aluminum. The Katana has a steel swingarm.
 I did the old bathroom scale method and the front end will be about 7 lbs lighter.  The rear is a wash, with the wider wheel, longer swingarm, etc. But I'll end up with better forks, brakes and wheel/tires.I

Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #18 on: Apr 03, 2018, 06:12:34 »
Following along. this is gonna be wild. what are your plans for stiffening the frame?

 I looked at some bracing used on race bikes and might be able to incorporate a couple. Keeping the side covers is a must, and tank clearance will be tight up front. I'm told Suzuki had some of the better,  stiffer frames of the era.

Offline scott s

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Re: 1980 GS550E + 2000 Katana 750
« Reply #19 on: Apr 06, 2018, 19:56:29 »
Took a band saw and a belt grinder to the Katana swing arm...







...did a whole bunch of measuring to find the center...







 ...and then a whole bunch MORE measuring to center it in the frame. Here, my Pop is mocking up the shocks and getting the angle correct so that we can get the lower clevis mounts welded on.