1980 GS550 + 2000 Katana 750

Discussion in 'Some Assembly Required' started by SCR100, Feb 1, 2018.

  1. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    Don't get the 2008 690 instrument panel. I'm on my 3rd one. Expensive fuckers, too.
    #41
    scot_douglas likes this.
  2. Kai Ju

    Kai Ju Long timer Supporter

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    TrailTech Vapor, does everything you need and more, easy to install. Cheap'ish
    #42
  3. Foxed101

    Foxed101 Monkeywrench

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    Nice one, putting a roller together out of the parts heap:clap

    Making good time on building the bike
    :thumb
    #43
  4. SCR100

    SCR100 Been here awhile

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    It doesn't look like much, but this pic represents working rear brakes with a much larger swing arm.
    I used a GS850 rear master (same as the 550 but with a longer push rod) and we bent the actuator arm from the 550. It's tight, but it clears. I'll use a banjo bolt style brake switch, since there's nowhere for the stock spring to fit now.

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    #44
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  5. SCR100

    SCR100 Been here awhile

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    I ran into a snag fitting the '95 BST-36 carbs. The manifolds that come with the carbs don't match the head. There's a HUGE mis-match to the ports. The old manifolds are taller and would cause the pods to hit the frame.
    Suzuki did a lot of superseding over the years, and parts were often used, discontinued, then brought back on another model, only to be superseded again. It makes researching parts VERY difficult.
    I'm going on the suggestions of a friend and I ordered a set of Bandit 1200 manifolds. Let's hope they work, since the 36's have been rebuilt and I bought a jet kit for them.
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    #45
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  6. SCR100

    SCR100 Been here awhile

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    I did pick up a Giuliari seat, though!

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    And I polished up the lips of the wheels to a satin finish, paint detailed the centers, and installed the rotors, which had also been detailed.
    New Shinko 712's were also installed.

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    #46
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  7. mentolio

    mentolio Been here awhile

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    Looking good! I have always liked wheels finished in that fashion (clean edges with painted centers).
    #47
  8. SCR100

    SCR100 Been here awhile

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    Fitted a GSXR 1100 fender to the Katana forks for more of an old school look.

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    #48
  9. SCR100

    SCR100 Been here awhile

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    Finally got the correct manifolds to fit the BST-36 carbs to the 750 head. These are used on GSXR1100's and Bandit 1200's.

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    #49
  10. SCR100

    SCR100 Been here awhile

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    The filters are a tight fit to the frame, but the motor goes where the motor goes. There's no way to tilt it forward or move it down anymore. The mashed part won't be visible once the tank is on.

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    And speaking of the tank, I'm going to have to raise the back slightly. The petcock would foul the filter otherwise. I'll probably trim off that small ear on the end of the lever for more clearance, too.

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    And come up with some sort of bracket here to lift the tank slightly.

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    Once I get that sorted, it'll be time to pull the engine and get it on the stand for detailing and a tune up, and to get the frame and swing arm painted up.
    #50
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  11. SCR100

    SCR100 Been here awhile

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    First, I want to apologize for the pics. My phone sucks and the light in my garage tends to wash it out. It's nearly impossible to get good pics in there. It looks like I used a potato instead of a camera!

    I have received a few comments/PM's about the shock and swing arm angle and length. I agree that it's steeper/longer than I would like, but there's a ton of work getting it centered and clearancing for the chain. Many of the pics showed the bike on the lift/center stand and the swinger drooped. I considered a different swinger; GS1100E, Bandit 1200, etc., but at this point I think it would be easier to work with what I have.

    I put the wheels back on the bike and set it down on it's on weight. The jack is just keeping the bike from tipping over, not lifting it at all. The shocks are 14" and set on the medium setting. I *still* feel like we could have laid down the shocks a bit more but, as you can see, the shock and swingarm angle aren't as bad as when it was on the center stand/lift and not rear wheel in.

    This is workable. And if it just handles too poorly or annoys me too much, I think it would be easier to go with some 13" shocks and maybe even have the chain adjuster slots machined longer and the end of the swingarm cut off a like amount. That would shorten the wheel base, lower the stance and lessen the swing arm angle. All without having to start from scratch.



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    #51
  12. 1 wheel peel

    1 wheel peel Been here awhile

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    Updates?
    #52
  13. SCR100

    SCR100 Been here awhile

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    Not much.

    Figured out the tank mounting. Got the petcock to (mostly) clear with some RamAir filters. The RamAirs use the stock rubber velocity stacks and supposedly help a LOT with tuning.

    I also got the gauges mounted.

    Hmmm.... guess I need to take some pics and do an update!
    #53
  14. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    You can do some parts bin engineering and look for carb mounting rubbers that have a steeper angle for better tank clearance. PITA to find ones that bolt on, but it's super sanitary when it works out.
    #54
  15. SCR100

    SCR100 Been here awhile

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    As promised, some pics.
    As often happens with projects, the work it takes to get it done doesn't look like much. But now the tank clears the carbs, the lines of the tank and seat are nice, the seat latch works, and the petcock (mostly) clears the air filter.

    I ended up using BST-36 carbs, Bandit 1200 manifolds, RamAir filters and Bandit 1200 rubber velocity stacks. The OldSkoolSuzuki guys swear that the RamAir filters/velocity stack combo makes for MUCH easier tuning. The RA filter squishes just enough to clear the petcock and leaves more than an inch behind the stack on the #1 throat.

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    I also re-did the top triple. I put the bar risers in a different spot and used a Bandit 400 dash. It's nearly invisible in the pic, but that black area between the gauges and the triple are idiot lights. The 4oo gauges use a cable drive speedo and the plug is (supposedly) nearly identical to the Katana plug and is supposed to be easy to swap around a wire or two to make it plug and play.
    They also have nice cups to hide the rear of the gauges, and it keeps it all in the Suzuki family.

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    #55
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  16. SCR100

    SCR100 Been here awhile

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    I've been pretty side tracked on projects lately. Been thinking about moving in a year or so and spent several weeks doing a "purge" around the house and garage. MASSIVE amounts of stuff to the dump and to Goodwill.
    Anyway, I've decided to work on the 1980 GS550 donor/spare parts bike this Winter. That way, I can maybe move it out next Spring and have one less thing in the garage. And one less project to worry about.

    Got the stock GS550 engine on the stand. It doesn't need a rebuild, but it was a leaker, so I'll re-seal it this Winter with fresh gaskets and such. The carbs are currently getting rebuilt with new diaphragms.
    The frame is a 1980 GS550E frame but, unbeknownst to me, that was the year that Suzuki stopped differentiating between the E and L bikes on the VIN number. I ended up with an L frame and an E donor.
    We cut the upper tank mounts off and I have a plan to get the tank rubber mounted through those lower holes, where it needs to be for an E tank.

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    I have a frame loop with a slight kick up that I will have welded on once the tank mounts are sorted. I will run a bobbed rear fender and a small tail light.

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    Zip Dawg approves.

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    #56
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  17. SCR100

    SCR100 Been here awhile

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    This bike is my inspiration for the spare parts bike. I will be able to run the stock carbs, exhaust and even the plenum, so that should really simplify tuning.
    I'd say I have about 90% of the parts needed to finish this one.

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    #57
    TonyKZ1 likes this.
  18. mentolio

    mentolio Been here awhile

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    I.LOVE.THESE.BUILDS. Keepitup!
    #58
  19. yycbarbarian

    yycbarbarian Adventurer

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    moar bike/ moar dog pics!
    #59
  20. SCR100

    SCR100 Been here awhile

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    Hehe... I sold the brat style project. It went to the right guy and he's making quick progress. I got side tracked on a CB550 project and haven't done much of anything on the GS550/750.
    #60