GT550 Rebuild and Restomod

[kadavenport]

Made some progress on the tear down.
Confirmed the fried piston and crank, but everything else looks good.

[kadavenport]

Anyone have a rattle can paint they suggest for touching up the frame?

[Alan H]

Black. Dark black preferred!

[kadavenport]

10-4 on the black. i may just go ahead and paint the whole frame, it's near completely stripped, so might as well remove the rest for paint.

[kadavenport]

Thanks to all the guys who posted on this thread: viewtopic.php?f=2&t=2992&hilit=Gt550+alternator
It was being stubborn, but the tricks on this thread made removing the alternator rotor so much easier.

[kadavenport]

Tuesday 3AM:
Woke up with a stomach virus, couldn't go back to sleep... so logically went down stairs and took the cases apart and cleaned them. Thought working on the bike would take my mind off being sick, and it worked for a little while .

This was my gentle touch to get the crank bolt off! It is a vintage impact that is awesome.


GT550 Open case:


Thursday night my dad came over and we spend a few hours cleaning stubborn gaskets off the cases cleaning parts.


I pulled an all nighter and got everything put together, torqued down (I love that Suzuki cast the torque order on the cases), and put the back in the bike.

[Alan H]

Looking good.
I went in my garage yesterday and rigged up a small air tool that I bought myself for Christmas, started up the 550 then went back in the house as it was -2 degrees C, that's about 27 ish in the US.
A bit warmer today - 0 degrees C so we're up to 32 F. Brrrr.
Roll on Barbados in 4 weeks!

[kadavenport]

I live in Atlanta, Ga so it's been between 50 - 60 degrees, I'm definitely spoiled when it comes to a warm work area.

[kadavenport]

I retorqued the clutch spring bolts and broke on off in the basket. I was able to extract it, but now I need to retread for a larger bolt. Has anyone had this issue before, this is the second time this has happened to me?

I'm thinking about tapping with 1/4in fine thread and using stainless steel Allen bolts.

[Alan H]

There was a thread about this not too long ago and how to sort it out.
If I find it I'll post a link or if anyone else knows where it is - please link to it.

[kadavenport]

Thanks, I'll search for it.

[kadavenport]

Engine filled with oil, and compression tested. All three cylinders read around 130 psi. Carbs mounted, but still need to wire it back up to start.

[kadavenport]

The spare head I had was a 1972 and was in better shape than my 75. Learned just how different the two heads are and the ram air shrouds are not interchangeable. So spent tonight swapping heads. The good news is that compression is even better than before and the bike is running. Hoping to post a video tomorrow.

[kadavenport]

Carbs back off, middle float is stuck pouring gas everywhere.

[Alan H]

Great fun these old bikes aint they?
Have you any hair left? Or is it just getting thinner as you tear the stuff out in handsfull?
Welcome to the club.