My Build: '80 GS 550L to Cafe Racer *Rejetting Finished*
- Thread starter Colorado CJ
- Start date
My Build: '80 GS 550L to Cafe Racer
Maybe some small led lights in the rear of your seat? Is that motor stock? Im building a gs250 currently and am look to eliminate as much electrics as possible and just run a small battery for horn, lights, instrument lights, kill switch ect. I plan to run a kick start engine.
Maybe some small led lights in the rear of your seat? Is that motor stock? Im building a gs250 currently and am look to eliminate as much electrics as possible and just run a small battery for horn, lights, instrument lights, kill switch ect. I plan to run a kick start engine.
Colorado CJ
New Member
Re: My Build: '80 GS 550L to Cafe Racer
Today I sandblasted and painted the headers/mufflers with some high temp ceramic header paint. They are hanging up in my storage shed drying.
Note: sorry for the mess, this is just a storage shed next to my shop
Today I sandblasted and painted the headers/mufflers with some high temp ceramic header paint. They are hanging up in my storage shed drying.
Note: sorry for the mess, this is just a storage shed next to my shop
Colorado CJ
New Member
Re: My Build: '80 GS 550L to Cafe Racer
I installed the pipes today and went through the carbs, painted the float bowls and tops of the carbs and installed them.
I should have all the controls and most of the electrics delivered in a few days. I can then start in on the rewiring job.
It is getting close to being finished. I see a day or two of rewiring. I'll then ride it a little to make sure everything is the way I want it. If it is, I'll strip it down for blasting and painting.
I think I'll go with blacked out everything and polish the motor up real well. I might make a shadow racing strip, or a very subdued racing stripe. Don't know yet.
Here's how the pipes look now. I like the look of these MUCH better than the big megaphones. They fit right up snug with the frame.
I installed the pipes today and went through the carbs, painted the float bowls and tops of the carbs and installed them.
I should have all the controls and most of the electrics delivered in a few days. I can then start in on the rewiring job.
It is getting close to being finished. I see a day or two of rewiring. I'll then ride it a little to make sure everything is the way I want it. If it is, I'll strip it down for blasting and painting.
I think I'll go with blacked out everything and polish the motor up real well. I might make a shadow racing strip, or a very subdued racing stripe. Don't know yet.
Here's how the pipes look now. I like the look of these MUCH better than the big megaphones. They fit right up snug with the frame.
Colorado CJ
New Member
Re: My Build: '80 GS 550L to Cafe Racer
Last night I won an ebay auction for a set '82 GS550 Katana forks and triple tree. These new forks look to be in great shape and they are air adjustable, so they are a decent upgrade from the stock forks. I payed $50.00 shipped for both the forks and the triple tree.
Those leading axle forks had to go!
Still looking for a cheap set of spoke wheels.
Last night I won an ebay auction for a set '82 GS550 Katana forks and triple tree. These new forks look to be in great shape and they are air adjustable, so they are a decent upgrade from the stock forks. I payed $50.00 shipped for both the forks and the triple tree.
Those leading axle forks had to go!
Still looking for a cheap set of spoke wheels.
Colorado CJ
New Member
Re: My Build: '80 GS 550L to Cafe Racer
On with the project. I started rewiring the bike last night. Everything is mounted to a 3/16" aluminum plate under the tank. Just enough room for everything including a 4-cell LiFE battery (just to the right of the rectifier.
I only got a few wires shortened/connected last night. I'm using very low resistance r/c connectors for most connections.
On with the project. I started rewiring the bike last night. Everything is mounted to a 3/16" aluminum plate under the tank. Just enough room for everything including a 4-cell LiFE battery (just to the right of the rectifier.
I only got a few wires shortened/connected last night. I'm using very low resistance r/c connectors for most connections.
RedPlastic
make it rain bitches
Re: My Build: '80 GS 550L to Cafe Racer *Rewiring Started*
looking pretty awesome...bit of advice though, you may wanna move that regulator/rectifier out in the open so some air can get to it. they tend to get kinda hot.
looking pretty awesome...bit of advice though, you may wanna move that regulator/rectifier out in the open so some air can get to it. they tend to get kinda hot.
Hoosier Daddy
Earache my eye...
Re: My Build: '80 GS 550L to Cafe Racer *Rewiring Started*
Nice to see another lowly "L" Model getting some lovin
I'm doin a '80 750 version myself.
I didn't do this so can't take any credit but I found it a while back on TheGSResources.com
Does this "550 Bobber Schematic .pdf" I attached help you out?
Nice to see another lowly "L" Model getting some lovin
I'm doin a '80 750 version myself.I didn't do this so can't take any credit but I found it a while back on TheGSResources.com
Does this "550 Bobber Schematic .pdf" I attached help you out?
Colorado CJ
New Member
Re: My Build: '80 GS 550L to Cafe Racer *Rewiring Started*
Thanks guys. Yeah I thought about air flow. There is acually quite a bit of room around the rectifier and it is open on the sides under the tank. The way the tank is shaped, it will actually force air to go over the rectifier when moving.
Hoosier Daddy, thanks for the pdf. I was pretty much finished noodling out all the wire colors on the schematic and your pdf helped out.
Finished the rewiring job. All I have left to do is put the battery connector on (will do that when the battery arrives). Here are a few pictures. (I'll have to reroute the one clear wire loom as it is too noticeable there)
Left over bits
Look ma! No electrics showing.
Thanks guys. Yeah I thought about air flow. There is acually quite a bit of room around the rectifier and it is open on the sides under the tank. The way the tank is shaped, it will actually force air to go over the rectifier when moving.
Hoosier Daddy, thanks for the pdf. I was pretty much finished noodling out all the wire colors on the schematic and your pdf helped out.
Finished the rewiring job. All I have left to do is put the battery connector on (will do that when the battery arrives). Here are a few pictures. (I'll have to reroute the one clear wire loom as it is too noticeable there)
Left over bits
Look ma! No electrics showing.
Colorado CJ
New Member
Re: My Build: '80 GS 550L to Cafe Racer *Rewiring Started*
I uploaded a video of the bike starting up for the first time since rewiring and installing shorty exhaust.
The bike actually sounds much better than this, The video was shot on my DSLR with the built in mic, so the sound isn't so good. The exhaust note sounds much lower in person.
The air sound is from the inlets. That will be quieter when I install the pod filters. It will also run better/go back to idle faster when I rejet the carbs.
GS550 Cafe Racer Build
I uploaded a video of the bike starting up for the first time since rewiring and installing shorty exhaust.
The bike actually sounds much better than this, The video was shot on my DSLR with the built in mic, so the sound isn't so good. The exhaust note sounds much lower in person.
The air sound is from the inlets. That will be quieter when I install the pod filters. It will also run better/go back to idle faster when I rejet the carbs.
GS550 Cafe Racer Build
Colorado CJ
New Member
Re: My Build: '80 GS 550L to Cafe Racer *Rewiring Started*
I think I got the jetting sorted. I used a set of number drills and kept going up until I thought it was right. I ended up going to a #55 drill, or a Minuki 118 jet size. I also adjusted each pilot screw to about 4.5 turns out and lifted the needles a little.
I can now loft the front wheel through the first three gear changes! So much more power than it had in it's stock configuration. It just keeps pulling to red line. There really are no flat spots, but at 7,000 r.p.m., there is a noticeable horsepower boost, feels like someone kicks you in the pants.
I have my LiFe battery installed and everything is working like it should. I still need to find a tail light (think I might go with flush mount LED's) and fabricate up a license mount. Once that is done, I'll ride it around for a couple of days before breaking it all down.
My new forks haven't arrived yet, it seems they just shipped them Friday.
Short video after the rejet (sound much better in person, my in camera mic on my DSLR isn't the greatest).
GS550 Jetting Finished
I think I got the jetting sorted. I used a set of number drills and kept going up until I thought it was right. I ended up going to a #55 drill, or a Minuki 118 jet size. I also adjusted each pilot screw to about 4.5 turns out and lifted the needles a little.
I can now loft the front wheel through the first three gear changes! So much more power than it had in it's stock configuration. It just keeps pulling to red line. There really are no flat spots, but at 7,000 r.p.m., there is a noticeable horsepower boost, feels like someone kicks you in the pants.
I have my LiFe battery installed and everything is working like it should. I still need to find a tail light (think I might go with flush mount LED's) and fabricate up a license mount. Once that is done, I'll ride it around for a couple of days before breaking it all down.
My new forks haven't arrived yet, it seems they just shipped them Friday.
Short video after the rejet (sound much better in person, my in camera mic on my DSLR isn't the greatest).
GS550 Jetting Finished
Colorado CJ
New Member
I just received my LED brake light today, so now everything is wired up and mounted in the proper places. I still don't have the Katana forks yet, but for now, I'll ride the bike as is to see if I need to change anything before breaking it down.
Here's a shot of the LiFE battery mounted. It sure is small compared to the stock battery. It only takes 50 amps to crank over the bike, so this battery is plenty powerful at 140 amps max. Cranks over the bike faster than the original battery.
Here's a shot of the LiFE battery mounted. It sure is small compared to the stock battery. It only takes 50 amps to crank over the bike, so this battery is plenty powerful at 140 amps max. Cranks over the bike faster than the original battery.
Colorado CJ
New Member
Here's a couple of pictures of the bike. I have the LED above the license plate. It is a Hyperlites S16 LED and is extremely bright, even in daylight. It strobes for 5 seconds, then stays fully lit when I apply the brakes.
I shot some rattle can paint on the seat pan so that I could ride it around for a while to see if I need to change anything before breaking it all down. (sandblasted steel rusts instantly if it gets wet).
Here's a picture of the LED running light on. It is MUCH brighter and more red in person, my camera didn't like to pick up on the red light for some reason.
I shot some rattle can paint on the seat pan so that I could ride it around for a while to see if I need to change anything before breaking it all down. (sandblasted steel rusts instantly if it gets wet).
Here's a picture of the LED running light on. It is MUCH brighter and more red in person, my camera didn't like to pick up on the red light for some reason.
Colorado CJ
New Member
I found my new forks waiting for me when I came home from work last night. I installed them and found that the calipers wouldn't work. I should have thought of that since the mounting would have to be different on the calipers because of the leading axle forks. No problem though, today I machined up a new bracket so that I could use the same caliper and not have to try to find one for a Katana.
These forks are MUCH nicer than the stock forks. No more brake dive and much better all around handling. I also filled the forks to 28 psi, they are nice and firm with good dampening. The new forks were also about 1.5" shorter, so mounting them dropped the front end and gave me less trail, so the bike really handles much better.
Well enough talking. Here's a picture. Don't mind the tape on the headlight, I burned out the bulb on my way home last night. I turned around and went back to the shop. Turns out my jeep lights plug right into the socket. A little electrical tape to hold the light in the fixture and I was able to ride home (it was late and dark).
Here's a picture of the bracket I machined to make the stock calipers work. The part I made is the dark black bracket that is mounted to the bottom caliper bolt.
These forks are MUCH nicer than the stock forks. No more brake dive and much better all around handling. I also filled the forks to 28 psi, they are nice and firm with good dampening. The new forks were also about 1.5" shorter, so mounting them dropped the front end and gave me less trail, so the bike really handles much better.
Well enough talking. Here's a picture. Don't mind the tape on the headlight, I burned out the bulb on my way home last night. I turned around and went back to the shop. Turns out my jeep lights plug right into the socket. A little electrical tape to hold the light in the fixture and I was able to ride home (it was late and dark).
Here's a picture of the bracket I machined to make the stock calipers work. The part I made is the dark black bracket that is mounted to the bottom caliper bolt.