1980 GS550E + 2000 Katana 750

scott s

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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.









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.
 

ridesolo

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Looking good. I think you'll be happy that this one didn't sell.
 

scott s

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Got a roller. It's about time to start working on the wiring harness and electrics.




 

scott s

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Not sure if anyone really cares or not, but I finally found some gumption to work on this thing again. Got the turn signals wired up today and ordered a battery. I have to find a frame ground for the GSX750F wiring harness. I think I can use the lower, front battery box bolt.

I got the Bandit 400 control wiring all figured out (I think) and I should be able to pop the battery in and see if any smoke gets out soon.



If it doesn't burst into flames, it won't be long until I add some gas and see if it starts!
 

scott s

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Woo Hoo! Put a battery in it today and it turns over with the starter! The oil light went out after a few revolutions. I have tail light, brake light (both front and rear switches), horn and a hi beam indicator.

Most importantly, I have spark from both coils!



I *don't * have headlight or turn signals, so I'll have to trace that out. I don't think I have backlights on the Bandit 400 gauges, but I do see the tach needle "twitch" when I power it up.

I'll sort out those things and then add gas and see if she'll run!
 

scott s

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Just checked and I DO have tach and speedo back lights. Just gotta figure out the headlight and turn signal situation.
 

scott s

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So....checked out the diagram and the harness.

Checked out the fuses: all good. Checked and I have power where I'm supposed to have power. I was trying to run an LED headlight and turn signals. Tried the old headlight bulb and it works. When I test the LED bulb off the bike, it works.



Same with the turns. When I test them with a spare battery, they work. My engine/harness is from a '00 750. It uses the wired, multi-prong relay, https://www.ronayers.com/oemparts/p/suzuki/38610-03f00/relay-turnsignal .



I'm about to hit the search button to see what everybody is doing for LED lights on a 2000 Suzuki Katana, but will this work?


https://www.customled.com/products/elfr-1-u-electronic-led-flasher-relay-7-pin-suzuki



Even if I get the turns to work with a good/different relay, what is keeping the LED headlight from working? Are there better ways to get the turns to work?
 

scott s

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OK.....found out that the prongs on the LED headlight bulb don't match the prong on the harness. I will work on depinning and repinning those when I have better light in the garage.

Found a 7 pin LED flasher relay for less than $14 shipped....have it on the way, too.

As soon as I get the wiring sorted and neaten it up a bit, I'll try firing her up!
 

scott s

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Swapped pins and got headlight to work. Yay!

Swapped polarity on all 4 turn signals and now they all light and blink (fast).
But they ALL blink. Left turn: all four.
Right turn: all four.

Could it be the indicator bulb in the dash, if it uses a single bulb? But the Katana and the Bandit (dash) both had a single bulb for the turns.
I'm not getting a turn signal indicator in the dash, either.
 

ridesolo

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I had a similar problem when wiring my 360/378. I ended up having to put a diode in line on both of my turn signal + wires to keep the DC going in one direction rather than sneak it's way through to places it shouldn't go. Check out this comment that @teazer made in my build:
If you have a singe idiot light for both indicators, check this out http://pinkpossum.com/Lights.htm
It was a big help for me to get it all sorted out. That situation and yours aren't exactly the same issue that I had but they were enough related that they required being sorted out pretty much the same way. Good luck!
 

scott s

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Today was fire up day!

At first, #1 was silly hot and #4 was cold-ish; and it was hard to get a nice idle. Some investigation found a diaphragm that wasn't seated properly on #4 and the intake manifold was crazy loose on #1. I guess I just forgot to tighten it up when I put it together. We fought it for a while, then just pulled the carbs and oil lines and tighten all of the manifolds while we were at it.

Seems to run pretty damn good now!

As a reminder: 2000 GSX750F engine, Yoshimura slip -on, BST-36 carbs with DynoJet kit, RamAir filters and a slotted timing advancer (stock, for now. I plan on going to a dyno soon).

 

scott s

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Got some pics, then took it apart again. I pulled the tach signal wire loose installing the tank, so that had to come off. Then I noticed some gas weeping around the petcock screws. I need to see if they use fiber washers. I also need some rubber grommets for the side covers. The clutch could use some adjusting and I want some pin stripes on the tail cowl.
But, overall, I'm pretty happy with it.









 

scott s

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I've only been up and down the street in front of my house so far. But I haven't crashed yet!
 

scott s

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What do you guys think.... doesn't the tail cowl need a little matching pin striping?


Got th ed petcock rubber bits in. Hope to get it all back together this weekend.
 

ridesolo

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Agreed on the tail striping. Aren't you glad it didn't sell? Great looking bike.
 

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