GS550E (project aborted, now for sale)

robmilkshakes

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Member introduction thread:
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Well here is my Suzuki as it sat a few days ago when I brought her home.


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She is in rather good mechanical condition aside from a few small imperfections. Its a pretty decent ten-foot bike as when you get up close a lot of little bits of 31 years of neglect start to show. When I received her, a previous owner had added the Kerker exhaust, pod filters, and rejetted the carb. I can't quite tell if the paint is original as it almost looks like it has been bondoed some underneath the paint. I plan to paint the tank and future seat this winter. Living in Baltimore means I will have a good four months to strip the whole bike down, paint and strip down the frame, repaint the tank and seat, and clean, clean, shine, and clean some more. As of now the side covers dont fit on very well, the tank at the very bottom edge is lightly rusted, the seat pan is rusting through and the seat is tore (but that isn't staying long), the kerker needs some paint (possibly a wrap), The bars and grips had seen better days, and after one full can of degreaser, I've barely made a dent.


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As you can see in the last picture she has been cleaned up some, new bars, grips, and bar ends fitted, and the oil has been changed.


List of things to do in the near future:


-Fab up mounting brackets for my new seat
-upholster or make a seat pad
-possibly paint the seat
-new taillight, license plate bracket, and turnsignals for the rear
-fix turnsignal on the front which is currently held on with tape and a ziptie
-fix the horn
-remove the airbox, and relocate the electronics and possibly the battery to open up the frame.
-paint the exhaust (maybe wrap it)
-Try to synch the carbs a little more
-paint the wheels
-restore the plastic bits
-bar end mirrors (maybe)
-possible brake job
-continue cleaning and maintenance/repair
-Fix the seemingly botched exhaust install.


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Either someone screwed up the exhaust install or this isn't quite for the right model as the passenger side footpeg is also melted some as when flipped down sits right on the muffler. The top shock mount doesn't move at all as it is, but I'd still like to take care of the bushing in the mean time before buying new shocks.


Overall I'm planning a mild cafe build with the goal of finishing next spring.
 
Re: GS550E cafe style project

Sweet bike man, I'm also doing a cafe GS550. How does that exhaust sound? I've seen one on youtube and it sounds beautiful. I just can't seem to find it anywhere. Only the mac 4 into ones. Anyways, good luck with the suzy!
 
Re: GS550E cafe style project

Always good to see another Suzuki around. Keep the updates coming man!
 
Re: GS550E cafe style project

The exhaust sounds pretty damn good. However, around midrange the bike seems to be leaning out a bit and the exhaust is popping on me some so I cant get a full idea on the exhaust sound. Who knows what the previous owner screwed up with the jetting hahah. Well in a few weeks, I'll probably remove the the carbs and give them a good cleaning and maybe try to richen up the fuel mixture with the jet needle. It'll be a fun (sarcasm) experience learning carbs as I've yet to ever really deal with them (what better way to learn than with quad mikunis, right?)

If I could come across a stock exhaust in good shape, I may return her to stock form with OEM jetting, if thats the case, I'll surely be selling the kerker.

I don't have much to update right now, as I've just been learning and enjoying the bike as-is for the past few days. However, my seat should be coming in in a few days so hopefully in two weeks I'll have a new seat and possibly a newly painted tank (likely just rattle canned, at least for this season). This is the only update I have, I couldn't resist with this helmet.

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Re: GS550E cafe style project

Thanks! I'm really happy with that helmet, and the rubatone version looks badass, I almost bought that instead.
 
Re: GS550E cafe style project

Well looks like I'll be buying tires soon. I got her out on the highway a bit yesterday and today, she feels a little uneasy at speed, and these older tires can't be helping the situation. Once thats sorted, on to fork oil and possibly new rear shocks. I may try to track down the stock exhaust after all, if thats the case, I'll be selling this kerker if anyone is interested.
 
Re: GS550E cafe style project

Fantastic motor, good transmission crap electrics (reg rect fails, generator burns out.
Get them re-wound when they die and you'll have a fantastic bike.
Around 1980, I built a 175+mph one for friend to go production racing.
Had a lot of work done to it, 620cc big bore, cams, 24 hrs porting intakes, (around 40~50 hrs on head work) race cams and hand made race exhaust.
Carbs were bored oversize as you had to use stock carb bodies
Passenger footrest does sit on the Kerker, not much you can do about it except make sure it doesn't go past 90 degrees.
Sometimes it's possible to fit mounting bracket on inside of footrest frame mount which moves it closer in and gives slightly more clearance.
That mount doesn't look right to me
Check swing arm bearings, they are probably worn/rusted out.
Suzuki used needle rollers and they rarely got greased
Put bike on center stand and grab rear wheel at 3:00 o'clock position then try pushing /pulling side to side,probably moves about 3/4"
 
Re: GS550E cafe style project

The exhaust has surface rust on the header and the rest of the pipe has light surface rust and the paint is flaking off a bit in places.

The charging issues with the bike have been worked out but will probably go through and double check it. I'll check out the swing arm bearings, something I forgot to do.

Thanks, pj! I'll update on these as soon as I check them out.
 
Re: GS550E cafe style project

Well, this past week I spent a lot of my free time finishing up another project for my other passion.

Anyway, this afternoon I spent some time going over the bike some more, the charging system seems to be working to spec, but I've yet to really thoroughly test everything but I haven't seen any reasons to really suspect the charging system. I have a valve cover gasket on order to check my valve clearances so I can make sure that all checks out and rule that out from my list of possible things causing my midrange flat spot. Some of that might just be the results of the kerker, at least from what I've been reading over on thegsresources.

As for the suspension, my rear swing arm bushings check out but when attempting to resolve my right side shock bushing issue I found my shocks were completely blown with zero rebound control, so I have a new set on order now. While its down waiting for those, I am painting my header, working on the new seat mounting, and cleaning everything more (I don't see an end to this!). I also want to check all my fuel lines and the petcock in the meantime.

A few from today:
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Also, first mock up of my seat. Its slightly too narrow to fit over the frame rails but I plan on using the stock corssmember to bolt the seat to and using rubber bushings to sit on the frame to isolate some vibrations. I still need to obviously cut the seat down and I'm probably just going to go with a simple seat pad or simple upholstered seat (along the lines of cafe pete's lucky 7even build).

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This is the other project I finished this week. The pink one is a prior attempt at a refinish from last year:

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Re: GS550E cafe style project

Do you slappa da bass? Or just paint em? I've been playing guitar for four years now.. well on and off. haha.
 
Re: GS550E cafe style project

I have played bass and guitar for 7 years now, but no slapping, it really doesn't interest me much actually hahah. Those are my personal instruments but do some repairs and stuff for others as well. Its one of the few things I know more about than cars I guess....
 
Re: GS550E cafe style project

Oh I see, I was just doing an "I love you man" reference. haha. That's cool man, I use to play in a band but now I just play for a bible study I do in the summer. It's really fun.
 
Re: GS550E cafe style project

I flipped the headlight mounts right to left on my GS. That drops the headlight about 2 inches. I'm only going to run the speedo and I'm making a mount the drops it closer to the lowered HL.
 
Re: GS550E cafe style project

Well I haven't had too much going on lately with the bike. My shocks finally came in and were installed. It feels so much better at speed now. I'd still like to get some progressive springs for the front though eventually.

Well right now I have a valve cover gasket on order, and I plan on ordering in carb rebuild kits for it someday soon as its needed. If I cant find a stock exhaust I'll just try shimming the needle to richen the mixture a bit midrange before I go significantly changing the jets when I'm not totally confident in what I'm looking for.

Also, I made a bit of a judgement regarding the bike, I don't believe that I will be continuing with the cafe project. I'm going to switch to more of a restoration. I would like to do a cafe eventually, but I just dont feel like this would be the right bike for it. Plus, the restoration route keeps it being a little nostalgic in my family between my father and I.

I do have a bit of a hacked up hotwingglass seat and some neoprene that I may try to sell in the near future. Currently I'm seeking a stock GS flat seat from ~78 or so but I'm not having much luck finding one.

I will post some pictures of progress soon.
 
Re: GS550E was cafe, is now a restoration project

Well, valve cover gasket is in, hopefully that'll take care of my oil leak. Also my intake and carb o rings came in from cycleorings.com which is a truely great source for these bikes.

Starting today Im going to take the carbs off, clean, dip, and rebuild them. Also, the engine will likely come out to get a thorough cleaning, valve adjustment, valve cover gasket, probably some paint and buffing as well. I may try to do a quick paint job on the frame while its out, nothing spectacular, but something that will hold me over til winter.

Also, I have been trying to track down a seat and intake manifold, I found a manifold out in Clarksburg, so hopefully he'll have a few other essentials as well when I get out there.
 
Re: GS550E was cafe, is now a restoration project

Well some sad news, I will likely be selling this in the very near future. I enjoy the bike but frankly between other projects its too much work for this season and I dont feel that the outcome, for me, will be worth the effort and money that I put into it.

I did rebuild the carbs and it is back to running but isn't running very well, it needs some definite carb work, possibly new OEM jets.

I do plan to continue riding, and do still plan to do a restoration in the future, but I will spend more time repairing this this season than riding so in the mean time will likely buy a newer bike in a little better shape (honestly looking at going to a Ninja 250)
 
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