DO THE TON

Blood Sweat Tears and Grease => Projects => Specials => Topic started by: scott s on Feb 01, 2018, 08:35:11

Title: 1980 GS550E + 2000 Katana 750
Post by: scott s 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.



 (http://i190.photobucket.com/albums/z189/uberkafer/GS550/25443301_10211052458053465_7746178894713202828_n_zpsfttdusfp.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/25443301_10211052458053465_7746178894713202828_n_zpsfttdusfp.jpg.html)



 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180130_105654_zpszhhujca3.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180130_105654_zpszhhujca3.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Feb 01, 2018, 08:39:40
The GS is already stripped down to a rolling chassis.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/26992655_10211341691564122_7104124769736584287_n_zpse2rvntlz.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/26992655_10211341691564122_7104124769736584287_n_zpse2rvntlz.jpg.html)



 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180130_140209_zpsfxamathx.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180130_140209_zpsfxamathx.jpg.html)

Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180130_105838_zpsbnlt3jnl.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180130_105838_zpsbnlt3jnl.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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?



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180131_101030_zpsjjc2boh5.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180131_101030_zpsjjc2boh5.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180130_140147_zpstzxoun2c.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180130_140147_zpstzxoun2c.jpg.html)

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180130_140108_zps92fudaqy.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180130_140108_zps92fudaqy.jpg.html)



 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180130_140045_zpsupmmriso.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180130_140045_zpsupmmriso.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/engine%20down1_zpsejxuvzkt.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/engine%20down1_zpsejxuvzkt.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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?
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: canyoncarver on Feb 02, 2018, 14:02:04
Sounds like you have quite a project with the motor swaps you are researching.  Looks like fun.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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).



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180208_195437_zpsfuhadybb.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180208_195437_zpsfuhadybb.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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!



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/bad%20caliper_zpsuyzcrt0c.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/bad%20caliper_zpsuyzcrt0c.jpg.html)



 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.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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:

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180212_141140_zpszettqomw.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180212_141140_zpszettqomw.jpg.html)



 After:

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180212_143749_zpsloktwk5y.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180212_143749_zpsloktwk5y.jpg.html)



 I'll keep working on the lips and polish them up, then I'll repaint the centers
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/carbs1_zps2ca4iqih.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/carbs1_zps2ca4iqih.jpg.html)

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/carbs2_zpspbdnq0jz.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/carbs2_zpspbdnq0jz.jpg.html)

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/carbs_zpsn0fawpsa.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/carbs_zpsn0fawpsa.jpg.html)

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/KampN%20RU2922_zpsjspc2yeu.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/KampN%20RU2922_zpsjspc2yeu.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180308_113353_zpsamzfqt4i.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180308_113353_zpsamzfqt4i.jpg.html)

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180308_113409_zpsp50xlp94.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180308_113409_zpsp50xlp94.jpg.html)



 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.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/dc104cl-vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-chassis-shock-parts-dcc-originals-diy-mount-clevi_zpsqedlpaog.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/dc104cl-vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-chassis-shock-parts-dcc-originals-diy-mount-clevi_zpsqedlpaog.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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!



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/s-l1600_zpstar1bgzy.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/s-l1600_zpstar1bgzy.jpg.html)

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/s-l1600%201_zps98stw5pb.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/s-l1600%201_zps98stw5pb.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: LightsOut 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?
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: doc_rot on Mar 28, 2018, 16:23:27
Following along. this is gonna be wild. what are your plans for stiffening the frame?
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s 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.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Apr 06, 2018, 19:56:29
Took a band saw and a belt grinder to the Katana swing arm...



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180405_140312_zpsnnojivtl.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180405_140312_zpsnnojivtl.jpg.html)



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



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180405_150841_zps4nqmkhtr.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180405_150841_zps4nqmkhtr.jpg.html)



 ...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.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/30128003_10211873412496813_889747233220591616_n_zpsdgcrewl9.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/30128003_10211873412496813_889747233220591616_n_zpsdgcrewl9.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: TripleKing on Apr 12, 2018, 23:35:03
The Pre Kat, which was air/oil cooled makes for an easier swap, as does a 600 Katana engine.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Apr 26, 2018, 14:20:32
 The 750 engine I'm using is air/oil cooled. It has the same dimensions as the 600 Katana engine. I am using a set of carbs from an earlier model for ease of tuning.

Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Apr 26, 2018, 14:21:00
 And now I have shock mounts. Ended up buying a second set of clevis mounts, turning one set from a I_I shape to an L shape, then boxing it in. Both sets of clevis' were welded together and then welded/boxed onto the swingarm.

 Now...on to the engine fitment!



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/8909_zps0f5eey4k.jpeg) (http://s190.photobucket.com/user/uberkafer/media/GS550/8909_zps0f5eey4k.jpeg.html)

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/8915_zpsrko6zaku.jpeg) (http://s190.photobucket.com/user/uberkafer/media/GS550/8915_zpsrko6zaku.jpeg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on May 31, 2018, 17:03:36
So, this happened....

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_135942_zps23zfaud5.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_135942_zps23zfaud5.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_140523_zpsriezpchy.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_140523_zpsriezpchy.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_140500_zps6qqv6mqe.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_140500_zps6qqv6mqe.jpg.html)

 Found a local guy that's an engineer and has some gab skills. He's doing all of this from his home garage. I couldn't be happier. He truly "gets" what I'm trying to accomplish and is doing quick, neat work. Today was just a "touch base and check on progress" kind of day and I'm thrilled.

 The rear upper mount is very nice and it, along with the lower RH mount, will be removable and make getting the engine in and out very easy.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_140129_zpsds1ejkeq.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_140129_zpsds1ejkeq.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_140239_zpsufhvl2yq.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_140239_zpsufhvl2yq.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_140200_zpsnisusu0t.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_140200_zpsnisusu0t.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on May 31, 2018, 17:06:21
The front mounts are the stock Katana mounts that he cut/modified and welded. The rubber dampener inserts were rather worn, so he made these aluminum spacers.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_140112_zpsvvom9o4s.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_140112_zpsvvom9o4s.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_142132_zpska5iwqns.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_142132_zpska5iwqns.jpg.html)

 He wasn't quite happy with that though, so he made theses Delrin spacers.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_141935_zpsnlmpk6gy.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_141935_zpsnlmpk6gy.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on May 31, 2018, 17:11:49
 I think it's gonna look really cool...and function great, too. He's still working on two of the lower middle engine mounts. We also checked header fitment and discussed the oil cooler mounting today.
 He's already checked chain alignment with a straight edge. Today, we ran the chain across the sprockets (I'm gonna need a longer chain) and it clears the frame, but is tight. The upper run can probably be cured with an acetylene torch and a ball peen hammer. The lower run may require some minor clearancing around the foot peg mount bosses. Switching to a 520 chain really helped.
 I'm also going to take the muffler with me next time I go and discuss a rear hanger for it.
 Oh, and he's going to work on the steering stop to prevent the larger forks from hitting the tank.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_141904_zpsncq4zeyk.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_141904_zpsncq4zeyk.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_143446_zps93viy8iv.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_143446_zps93viy8iv.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180531_143420_zpsnswwt6kb.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180531_143420_zpsnswwt6kb.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: doc_rot on May 31, 2018, 21:39:38
wow this is gonna be awesome.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Jul 23, 2018, 12:36:30
 Picked up the GS/Kat project from the welder about a week ago. I'm really happy with the quality of his work and his solution to some of the things we faced. It helps when your welder is an engineer, too!

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180714_134437_zpslcd3woh4.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180714_134437_zpslcd3woh4.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/91098d7d-2feb-47e5-acab-47d41c4a3d6a_zps8ks01mgs.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/91098d7d-2feb-47e5-acab-47d41c4a3d6a_zps8ks01mgs.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20180714_134502_zpsvrde8wx6.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20180714_134502_zpsvrde8wx6.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Jul 23, 2018, 12:38:24
 When I got it home I couldn't help but slap on some bodywork and see what it might look like!

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/mock%20up_zpskp8ruc8l.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/mock%20up_zpskp8ruc8l.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/mock%20up1_zps5zpxqmri.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/mock%20up1_zps5zpxqmri.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Jul 23, 2018, 12:42:31
 Been kicking around ideas for the gauges/dash. I have these early GSX-R 750 clocks, and I found a speedo drive that fits my wheel, but they're incomplete. I'd have to come up with some idiot lights and some sort of pod/dash/flyscreen to finish them off.
 I like the idea of old school analog gauges. But it might be easier to go with something modern. There's also the possibility of fitting a dash from a Bandit 1200 or similar.
 This is something I still need to figure out.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/GSXR%20dash_zpsmrxunsqf.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/GSXR%20dash_zpsmrxunsqf.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Jul 23, 2018, 12:48:58
  Then I stripped it all back down again.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/stripped%20again_zpsm5fj3nen.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/stripped%20again_zpsm5fj3nen.jpg.html)

I spent a couple of hours this morning making my fingers sore. When I stripped the wheels a while back, I noticed some oxidation. I went through a couple of grades of sand paper, then switched to several stages of SkotchBrite pads.
 At this stage, they have a nice brushed/satin finish. I'm 95% sure I'm going to stop there. I need to decide whether I want the centers black or graphite.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/satin%20wheels_zpstolmvqhj.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/satin%20wheels_zpstolmvqhj.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/satin%20lip_zpspu1tbdem.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/satin%20lip_zpspu1tbdem.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Jul 23, 2018, 13:56:19
Also, since I originally intended to fix up the GS550 with more of a stock vibe, I had started collecting some parts before I went the GSX750 route.
I was tired of tripping over parts in the garage, so I took the spare frame I got from eBay and cleaned it up and painted it. I rebuilt the forks with new seals/oil, Sonic spring and valve emulators. Found a nice set of used Koni shocks for the rear. Cleaned and greased all bearings, etc. Cleaned, painted and polished up the stock wheels and installed slotted rotors from a later model.
Turned out pretty nice considering I used parts I had on hand and lots of elbow grease. This one will get the stock GS550 engine (after I re-seal it), carbs and exhaust, plus some custom bodywork. In the mean time, it's easier to store a rolling frame than piles and piles of parts.


(http://i190.photobucket.com/albums/z189/uberkafer/GS550/spare%20frame_zpshxblizcf.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/spare%20frame_zpshxblizcf.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/spare%20frame1_zpszhgwinjs.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/spare%20frame1_zpszhgwinjs.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/spare%20frame2_zpsfukeqr1f.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/spare%20frame2_zpsfukeqr1f.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/spare%20frame4_zpscpbbhp9j.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/spare%20frame4_zpscpbbhp9j.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/spare%20frame3_zpsz7bbmutb.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/spare%20frame3_zpsz7bbmutb.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Aug 17, 2018, 14:47:17
 It doesn't look like much, but this pic represents working rear brakes with a much larger swing arm.
 I used a GS850 rear master (same as the 550 but with a longer push rod) and we bent the actuator arm from the 550. It's tight, but it clears. I'll use a banjo bolt style brake switch, since there's nowhere for the stock spring to fit now.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/rear%20master_zpsvzvjngze.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/rear%20master_zpsvzvjngze.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Aug 17, 2018, 14:52:58
 I ran into a snag fitting the '95 BST-36 carbs. The manifolds that come with the carbs don't match the head. There's a HUGE mis-match to the ports. The old manifolds are taller and would cause the pods to hit the frame.
 Suzuki did a lot of superseding over the years, and parts were often used, discontinued, then brought back on another model, only to be superseded again. It makes researching parts VERY difficult.
 I'm going on the suggestions of a friend and I ordered a set of Bandit 1200 manifolds. Let's hope they work, since the 36's have been rebuilt and I bought a jet kit for them.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/manifolds_zpsome4jpr3.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/manifolds_zpsome4jpr3.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Aug 17, 2018, 14:56:11
 I did pick up a Giuliari seat, though!

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/Giuliari%20seat%20correct1_zpsf6cexbvh.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/Giuliari%20seat%20correct1_zpsf6cexbvh.jpg.html)

 And I polished up the lips of the wheels to a satin finish, paint detailed the centers, and installed the rotors, which had also been detailed.
 New Shinko 712's were also installed.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/new%20tires_zpsghtgzhes.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/new%20tires_zpsghtgzhes.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/new%20tires1_zpstyrv1hbc.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/new%20tires1_zpstyrv1hbc.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Aug 23, 2018, 17:52:52
Fitted a GSXR 1100 fender to the Katana forks for more of an old school look.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/front%20fender_zpswjwlsjd2.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/front%20fender_zpswjwlsjd2.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/front%20fender1_zpsjphauavn.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/front%20fender1_zpsjphauavn.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/front%20fender2_zpspq6jfmyc.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/front%20fender2_zpspq6jfmyc.jpg.html)

Finally got the correct manifolds to fit the BST-36 carbs to the 750 head. These are used on GSXR1100's and Bandit 1200's.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/carbs%20in1_zps3hofn5ud.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/carbs%20in1_zps3hofn5ud.jpg.html)

The filters are a tight fit to the frame, but the motor goes where the motor goes. There's no way to tilt it forward or move it down anymore. The mashed part won't be visible once the tank is on.


(http://i190.photobucket.com/albums/z189/uberkafer/GS550/carbs%20in_zpsf1rvwb2g.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/carbs%20in_zpsf1rvwb2g.jpg.html)

 And speaking of the tank, I'm going to have to raise the back slightly. The petcock would foul the filter otherwise. I'll probably trim off that small ear on the end of the lever for more clearance, too.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/petcock_zpspczjidm2.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/petcock_zpspczjidm2.jpg.html)

 And come up with some sort of bracket here to lift the tank slightly.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/rear%20tank_zps1qqmhgbu.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/rear%20tank_zps1qqmhgbu.jpg.html)

 Once I get that sorted, it'll be time to pull the engine and get it on the stand for detailing and a tune up, and to get the frame and swing arm painted up.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Aug 30, 2018, 15:38:33
 First, I want to apologize for the pics. My phone sucks and the light in my garage tends to wash it out. It's nearly impossible to get good pics in there. It looks like I used a potato instead of a camera!

 I have received a few comments/PM's about the shock and swing arm angle and length. I agree that it's steeper/longer than I would like, but there's a ton of work getting it centered and clearancing for the chain. Many of the pics showed the bike on the lift/center stand and the swinger drooped. I considered a different swinger; GS1100E, Bandit 1200, etc., but at this point I think it would be easier to work with what I have.

 I put the wheels back on the bike and set it down on it's on weight. The jack is just keeping the bike from tipping over, not lifting it at all. The shocks are 14" and set on the medium setting. I *still* feel like we could have laid down the shocks a bit more but, as you can see, the shock and swingarm angle aren't as bad as when it was on the center stand/lift and not rear wheel in.

 This is workable. And if it just handles too poorly or annoys me too much, I think it would be easier to go with some 13" shocks and maybe even have the chain adjuster slots machined longer and the end of the swingarm cut off a like amount. That would shorten the wheel base, lower the stance and lessen the swing arm angle. All without having to start from scratch.



(http://i190.photobucket.com/albums/z189/uberkafer/GS550/swingarm%20angle1_zps8hkhtw1a.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/swingarm%20angle1_zps8hkhtw1a.jpg.html)

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/swingarm%20angle_zps2r168q2c.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/swingarm%20angle_zps2r168q2c.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Nov 15, 2018, 13:04:51
As often happens with projects, the work it takes to get it done doesn't look like much. But now the tank clears the carbs, the lines of the tank and seat are nice, the seat latch works, and the petcock (mostly) clears the air filter.

 I ended up using BST-36 carbs, Bandit 1200 manifolds, RamAir filters and Bandit 1200 rubber velocity stacks. The OldSkoolSuzuki guys swear that the RamAir filters/velocity stack combo makes for MUCH easier tuning. The RA filter squishes just enough to clear the petcock and leaves more than an inch behind the stack on the #1 throat.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/tank%20mount%20done_zpssnotuauz.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/tank%20mount%20done_zpssnotuauz.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/tank%20mount%20clear_zpszg9gbqmo.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/tank%20mount%20clear_zpszg9gbqmo.jpg.html)

 I also re-did the top triple. I put the bar risers in a different spot and used a Bandit 400 dash. It's nearly invisible in the pic, but that black area between the gauges and the triple are idiot lights. The 4oo gauges use a cable drive speedo and the plug is (supposedly) nearly identical to the Katana plug and is supposed to be easy to swap around a wire or two to make it plug and play.
 They also have nice cups to hide the rear of the gauges, and it keeps it all in the Suzuki family.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/400%20dash4_zps1tsib1qe.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/400%20dash4_zps1tsib1qe.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/400%20dash5_zpskm86ghae.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/400%20dash5_zpskm86ghae.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Nov 15, 2018, 13:14:07
 I've been pretty side tracked on projects lately. Been thinking about moving in a year or so and spent several weeks doing a "purge" around the house and garage. MASSIVE amounts of stuff to the dump and to Goodwill.
 Anyway, I've decided to work on the 1980 GS550 donor/spare parts bike this Winter. That way, I can maybe move it out next Spring and have one less thing in the garage. And one less project to worry about.

 Got the stock GS550 engine on the stand. It doesn't need a rebuild, but it was a leaker, so I'll re-seal it this Winter with fresh gaskets and such. The carbs are currently getting rebuilt with new diaphragms.
 The frame is a 1980 GS550E frame but, unbeknownst to me, that was the year that Suzuki stopped differentiating between the E and L bikes on the VIN number. I ended up with an L frame and an E donor.
 We cut the upper tank mounts off and I have a plan to get the tank rubber mounted through those lower holes, where it needs to be for an E tank.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20181108_094313_zpsn9xblyoc.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20181108_094313_zpsn9xblyoc.jpg.html)

 I have a frame loop with a slight kick up that I will have welded on once the tank mounts are sorted. I will run a bobbed rear fender and a small tail light.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20181108_101843_zpsblei7f4l.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20181108_101843_zpsblei7f4l.jpg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20181108_101829_zpse8kopiu6.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20181108_101829_zpse8kopiu6.jpg.html)

 Zip Dawg approves.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/20181108_101852_zpspagwdvjh.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/20181108_101852_zpspagwdvjh.jpg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Nov 15, 2018, 13:17:25
 This bike is my inspiration for the spare parts bike. I will be able to run the stock carbs, exhaust and even the plenum, so that should really simplify tuning.
 I'd say I have about 90% of the parts needed to finish this one.

(http://i190.photobucket.com/albums/z189/uberkafer/GS550/Suzuki-GS550-Bratstyle-1-1024x768_zpsnngbdlfg.jpeg) (http://s190.photobucket.com/user/uberkafer/media/GS550/Suzuki-GS550-Bratstyle-1-1024x768_zpsnngbdlfg.jpeg.html)
(http://i190.photobucket.com/albums/z189/uberkafer/GS550/Suzuki-GS550-Bratstyle-3_zpstjq2idfc.jpeg) (http://s190.photobucket.com/user/uberkafer/media/GS550/Suzuki-GS550-Bratstyle-3_zpstjq2idfc.jpeg.html)
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Jun 12, 2019, 14:29:20
Not gonna lie.... took a big, long break from this project. Had life get in the way over the winter. Had lots of other distractions and, honestly, I just lost interest in it. I sold the Brat project with the stock 550 engine. I even tried to sell the 750 swap project and, I guess you could say luckily, I had no takers.



 So... I took it apart and started working on it again.



(https://i190.photobucket.com/albums/z189/uberkafer/GS550/model%20kit_zps589acadj.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/model%20kit_zps589acadj.jpg.html)

(https://i190.photobucket.com/albums/z189/uberkafer/GS550/engine%20out1_zpslzh51sq1.jpg) (http://s190.photobucket.com/user/uberkafer/media/GS550/engine%20out1_zpslzh51sq1.jpg.html)



 I got the frame, swing arm and various bits and hangers painted yesterday. Today, I adjusted the valves (all were within specs but I snugged up the intakes just a bit) and slotted the timing advance plate to I can try advancing the timing once I get it running.

 I tried to install the starter motor I bought a year ago only to find that I had a -'98 starter and I have a '00 motor. Doh! Got the correct one ordered and once it's installed I'll get the engine back in the frame and start putting this thing back together.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: ridesolo on Jun 17, 2019, 18:36:07
Looking good.  I think you'll be happy that this one didn't sell.
Title: Re: 1980 GS550E + 2000 Katana 750
Post by: scott s on Aug 25, 2019, 16:35:56
 Got a roller. It's about time to start working on the wiring harness and electrics.

(https://i.imgur.com/h7REgRj.jpg)
(https://i.imgur.com/VlpJunc.jpg)
(https://i.imgur.com/H3my9yT.jpg)
(https://i.imgur.com/WA8uI34.jpg)