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Author Topic: First build, 1977 GS550  (Read 3008 times)

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #10 on: Dec 24, 2017, 14:20:34 »
I wish more pictures were taken at this point, if I was a better fabricator it would have been a heck of a lot less grinding and sanding.  Was about a two day process to get this how I wanted.  But its done now and good enough for me!

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #11 on: Dec 24, 2017, 14:26:18 »
There were about 4 different versions of the battery/ electrical component mounts made, I'd dream one up over a week, build it, then have a better idea a week later.  Repeat...

But as a bonus, some of the parts were showing up, originally I wanted to do an electronic speedo, with tack and make it more modern, but there is something about analog gauges that are so much cooler, and really its a 40 year old bike.

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #12 on: Dec 24, 2017, 14:28:33 »
And yes, Renthal bars, motocross is my main passion/ hobby, seemed silly to have anything else.

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #13 on: Dec 24, 2017, 14:32:41 »
At this point, believe it or not, it still had not run!  Not even tried too, figured that would be the easy part, since it had compression, but that was getting to be the focus.

The foot controls were not really turning out how I wanted, the bushings were not a tight fit, they had too much wobble in them, so they were changed a bit, no sense sending them back and paying more for something else.

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #14 on: Dec 24, 2017, 14:37:36 »
McMasters is an awesome company!  I needed a .001 type clearance from bushing to pivot point, the controls I bought were around .006 ish, a little cutting and welding later...  Plus they needed to be spaced out from the frame an inch or so.  Much better now, the rear brake was more of a pain.

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #15 on: Dec 24, 2017, 14:46:08 »
Now, I'm sure with enough time and patience, a guy could make sense of the stock wiring...  The copy of the diagram that was in the manual was more than difficult to read, plus the stock connectors were giving readings anywhere from .1 to 100 ohms.  Not good.  And to top it off, the goofy, in my opinion, way that one leg of the generator was routed through the high beam, then back to the voltage regulator = I'm an electrician, modern electronics are relatively cheap = complete rewire takes about 2 hours, done.

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #16 on: Dec 24, 2017, 14:53:10 »
Once the wiring was completed, sorry, didn't take any final pictures of that yet.  I was able to fire it up.  It ran, rather poorly, the carburetors were leaking gas like crazy, they needed to be cleaned and rebuilt, but on with the project.  Watched a youtube video from Dimecity cycles on how to make a rear cowl.  Figured, how hard can it be...  My dad and I did a fair amount of fiberglass work when I was a teenager, first restoring a pontoon boat, then restoring his old dune buggy that suffered some damage from a heavy snow storm collapsing the building the car was stored in.

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #17 on: Dec 24, 2017, 15:03:36 »
Now its starting to take shape, I'm no artist so making things from scratch like this usually results in several attempts to get the final product to look like the idea in my head, but this one I got lucky.  Still at this point not figured out how its going to be mounted, but hey, full speed ahead!

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #18 on: Dec 24, 2017, 15:08:06 »
Soaking the carburetors in Pine sole and water over night works like magic, still blown away at how well it works.   

Offline kevinj0101

  • Posts: 29
Re: First build, 1977 GS550
« Reply #19 on: Dec 24, 2017, 15:09:04 »
Bondo time!