So here’s the original thread. It’s a long and winding read. I’ll summarize what has been done already and where I’m looking to go a few posts down..
Sorry - something didn't work - likely a dead link

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Maybe (at least for me) hesitant to follow the "hack" comment, as at least on first glance it looks quite right. Do you have any changes planned or in progress that you care to clue us on?Tough crowd. Alright it’s me, I’m the hack (literally). I stumbled my way through building this bike with the help of this forum a decade or so ago. Then sold it shortly after and have regretted it since. A couple months ago I was given the opportunity to buy it back and you bet your ass I did.
The list will evolve as I get into it, but right now I know it needs new valve guides and seals, and I probably ought to just go new valves and heavier springs too. And sheesh maybe a light port job. I forget which cam I installed the first time, but it feels like it wants to breathe better at higher rpms.Maybe (at least for me) hesitant to follow the "hack" comment, as at least on first glance it looks quite right. Do you have any changes planned or in progress that you care to clue us on?
Hey Mike!Ha. Welcome back! That is still one of my top favorite bikes from any DTT member!
Well it seems like the cafe craze is finally winding down, so, buyers market baby!Glad to see you and the bike back! I've been thinking about chasing my XS that I sold down and buying it back for 1/2 of what I sold it for![]()
Thanks, yeah it’s virtually unchanged from when I sold it. Couple nice new machined parts that the owner finished but that’s it. Stoked.Great build from the start. Nice to see you get it back. I had a chopper come back into my garage that I had sold 3 years before. I tried to get it back, but the guy hadn't finished ruining it yet. Glad yours has stayed mostly intact.
Thanks dude!I am one man who understands sellers remorse! Beautiful bike.
Hey teazer! Thanks for talking a little sense into me. No plans to increase the bore, I think I’m pretty much at the limit already and I’d hate to turn those nice pistons into paperweights. Would you do anything on those pitted lobes to prevent trashing the new rockers? Carefully taking some rough edges down maybe? I know this isn’t the right answer, but what do you think about TIG welding the pits with some hard facing filler, A73 rod maybe?Pistons are bore look fine from here. The crowns will clean up ok and that minor rust pit in the liners is low enough to make very little difference - unless you are thinking of going larger bore anyway. If you go much larger on the bore you may have to consider a 650 top end to get enough air in.
But unless that's where you want to go, try to use what you have. Shops like my guy in Australia 2 decades ago or Pete Fischer at Powroll ( I think that he may have crossed the rainbow bridge too) those guys used to be set up to line bore the head and cover to take split bronze bushes. See if there's anyone that can do that.
The cam and bearings don't look too bad depending on your planned next steps. They show wear and rust pitting and so on but are probably usable without losing much power or longevity. Of course it would be better with all new parts, but you might be surprised how worn parts can be before they absolutely have to be replaced. That's why I tell people not to pull a crank out if the bike is running just fine. Once you see wear and pitting, you cannot unsee it. If you want to replace/repair parts and have the budget or a good source of cheap replacements, don't be too much of a perfectionist.
If parts are way out of round or lost oil pressure or compression is low, that's different. Oil seals on the guides? Go for it. Wear in the guides? measure it and see if it's still in spec. I like everything in a race motor or a bike I am selling to be first class, but there are limits for a reason....
Irk knows what bits go together on those motors and might have some ideas.
Gotta love eBay, I got lucky today finding everything I need to fix it!Don't know about a 550, but I ruined the right head and cam on a GL1000 last summer (total loss of oil caused by a &*%#@ PO's use of RTV), ebayed another for $100 and transfered over valves (new) and springs. Running smooth now.