Front sprocket GT550

[kawonda750]

I have the engine almost completely assembled. Just waiting on SRIS tubes to finish.
The front sprocket has a little bit of side play when tightened down and I am pretty sure it shouldn't. The bolts are tight. I put the inner locking washer over the "teeth" on the shaft and then spin it in the groove on the shaft to match up the bolt holes. I have the washer to lock down the bolt heads on next. There is a slight sideways movement of the sprocket.
Is it a bad sprocket? Or do I have something on wrong?

[markush]

neither nor
The attachment of the sprocket on the GT550/380 is actually a bit rickety.
The play increases during use because the holding plate wears out at the contact points due to the (small amount of) possible movement and becomes thinner there. Therefore, when changing the sprocket, it is better to use a new plate.

IMG_0013.JPG

[Alan H]

A couple of spots of weld will stop any looseness, but a less than optimal move really!
I've seen new ones on ebay & elsewhere - part number 27512-33000
It helps if you fit a new (same size) sprocket. The part above only locks the sprocket in place.

[kawonda750]

Ok. Thanks to both of you. I am learning the special things about Suzukis as opposed to those about Kawasakis. I will get a new sprocket and the washer for good measure. Just waiting on SRIS hose to complete the engine. It is really heavy assembled and should be fun to get it into the frame.

[Alan H]

Lay the engine on its side and lower the frame onto the engine. Even easier with the wheels and forks off.
Or.....
I usually build the rolling chassis, then swing the bottom end into the frame. (No barrels, head, pistons, clutch etc. so the 'engine' is at it's lightest.)
Rope around the cases and swing it in. Get front top engine bolt in and the others are easy.
Careful of your fingers - don't ask why I said that!

[jabcb]

To install the T500 motor in the rolling chassis, I used two step stools & two pieces of wood. A pic of this setup is in my T500 build topic.

For the GT550 build, had a young strong friend help. Before I finished explaining how we would install it, he picked up the motor & swung it into place.

[kawonda750]

I have a strong friend to help me lift it down off the bench and on to my wheeled lift. I push it to the bike stand which is down all the way and then jack the engine to the correct height and , with help, lift it into the frame. So far, it has worked for me. Sometimes a crowbar to lever it into the right position to get the engine bolts in.

The key is the strong friend or, if in a real pinch, my son has a friend who is massive and works out who lifted my GT750 engine like it was a loaf of bread.... Iam sure that I was that strong a few years ago....

[kawonda750]

I received a new sprocket yesterday and installed it with the same results. It still has some side play. I am waiting for a new fixing washer to arrive which was ordered last week. Hopefully it fills the extra space in the groove in the shaft and will cure the side play.

[kawonda750]

Progress has been good. Only waiting on the sprocket retainer and then I can put the clutch activator on. I am waiting on the foam air filters but want to leave the airbox off until I can make sure the carbs are right with a vacuum gauge.

[Alan H]

Easy to do them off the bike. Turn the tickover screw so that the slides are just open, then ensure that the 3 slides are all set exactly the same height by adjusting the individual screw adjusters on each slide - use a feeler gauge or thin rod to see when they start to lift - this must be exactly together. I've never needed a vacuum gauge.
Fit carbs and start the engine and adjust the tickover so it runs at about 1000rpm. For the first start after a rebuild, on the linked carb models I always fit the airbox but not the actual filters or side plates and just give a couple of squirts of easy start into the airbox. Easier if bike is on the centre stand so all 3 carbs are full, choke on & spin the engine. If it doesn't run clean, short squirt of easy start into the airbox should help. I use B6ES plugs for the initial start & first 10-15 miles until thhe fog clears. Keep revs below 4000 with B6 plugs, then go to B7ES for running in. Keep revs below 5-6000 for a couple of hundred mikes, then decide if you think it's run in or not - go to B8ES to use more throttle for longer times.

[kawonda750]

I guess that I am treating this bike like a Kawasaki. I have to learn the nuances of the Suzukis rather than my usual Kaws. I have done the carbs off the bike according to the manual's set up instructions. We'll see what is what soon enough. Probably a couple more weeks until Mother Nature's Canadian sister lets us open the garage doors....

[kawonda750]

I have finally received the sprocket retainer washer. It was lost in shipping and the vendor finally sent a replacement. The 550 is complete. Now, if it would only stop raining, I can bring it outside, add gas and start , or try to start it.

I would add gas and just open the garage door but what usually happens is a float is stuck or some other problem resulting in fuel on the floor and the dreaded " I SMELL GAS" from my wife. She can smell gas from somewhere around 12 miles away.

Looks loke the rain will have stopped by Monday...

[kawonda750]

This never happens. I put gas in and it started in seconds on all 3 cylinders. Adjusted the idle a bit. Runs nicely. The clutch works and it shifts gears well. Must be cuz it's a Suzuki.

[Alan H]

Yup. My 550s are like that too.