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PostPosted: Sat Jan 27, 2018 9:24 am 
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Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
Posts: 3145
Location: southwestern Pennsylvania
Country: USA
Bikes owned: 69 T350 thru 75 GT750
Another question for the ’72 GT550 cafe build.

Am wondering what is the best/easiest way to install the GT550 motor in the frame.
We did a completely disassembly/rebuild for the GT250 cafe project. That motor wasn’t particularly heavy.
For an old guy like me, the T500 motor is heavy but still doable with a helper, but the GT550 motor is f*** heavy.

Am working on turning the GT550 into a rolling chassis while waiting for the crank rebuild.
Am now wondering about the best assembly procedure. Should we install the motor in the frame before or after we assembled the rolling chassis?

Any suggestions?

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BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 73 project
T350 69, 71 & 72 project
T250 72
Honda 85 CB650SC & 86 CB700SC
Yamaha 75 XS650
09 Triumph Bonneville SE


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PostPosted: Sat Jan 27, 2018 11:51 am 
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To the on ramp

Joined: Tue Mar 10, 2015 12:35 pm
Posts: 349
Location: Wales
Country: WALES
Bikes owned: suzuki gt 550j
I just put bottom half of motor in first and then put barrels on after. Did it myself used foam pipe insulation to protect frame and trolley jack underneath to raise motor for mounting bolts.

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98 carb Blackbird and GT550j


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PostPosted: Sat Jan 27, 2018 12:48 pm 
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World Superbike
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Joined: Thu Feb 16, 2012 11:50 am
Posts: 2107
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
I swung mine in (less barrels, head, carbs) on a pulley block fastened to the garage roof.
Did that on two different 550s.

Or lay the engine on its side and lift the frame over the engine.
Use a friend to help!


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PostPosted: Sat Jan 27, 2018 3:17 pm 
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Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
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Location: southwestern Pennsylvania
Country: USA
Bikes owned: 69 T350 thru 75 GT750
The foam pipe insulation is a good suggestion.

How did you attach the motor to the pulley?

_________________
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 73 project
T350 69, 71 & 72 project
T250 72
Honda 85 CB650SC & 86 CB700SC
Yamaha 75 XS650
09 Triumph Bonneville SE


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PostPosted: Sat Jan 27, 2018 3:49 pm 
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World Superbike
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Joined: Thu Feb 16, 2012 11:50 am
Posts: 2107
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
Rope through bottom rear engine mounts and bottom front engine mounts in a loop. Lift engine slightly front low.
Lift point above top frame tube, not central. Push engine into frame and lower until front top engine bolt will go in. You can then put a jack under the engine (or a piece of wood between engine and frame bottom rails) and remove the rope. Lower the back of the engine and fit the other bolts. Fit the side plate last.

Sounds complicated, but I did it on my own with both rebuilds and it was easy!


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PostPosted: Sat Jan 27, 2018 4:09 pm 
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World Superbike
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Joined: Thu Feb 16, 2012 11:50 am
Posts: 2107
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
I've a couple of pics of the lift, but they're 2000 miles away on the laptop!
I can post 'em in a week or so, unless you're in a rush!!!


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PostPosted: Sat Jan 27, 2018 6:12 pm 
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Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
Posts: 3145
Location: southwestern Pennsylvania
Country: USA
Bikes owned: 69 T350 thru 75 GT750
Thanks.

There is no rush. Probably will be another month before we’re ready to start assembling the GT550 motor. And I haven’t even started on polishing + clear coating the motor covers.

_________________
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 73 project
T350 69, 71 & 72 project
T250 72
Honda 85 CB650SC & 86 CB700SC
Yamaha 75 XS650
09 Triumph Bonneville SE


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PostPosted: Sun Jan 28, 2018 3:01 am 
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World Superbike
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Joined: Thu Feb 16, 2012 11:50 am
Posts: 2107
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
Clear coat tends to 'yellow' with engine heat.


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PostPosted: Sun Jan 28, 2018 2:09 pm 
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On the main road

Joined: Fri Aug 11, 2017 7:09 am
Posts: 184
Country: england
Bikes owned: several gt250 ramairs
i presume you have the bank of 3 carbs?
to pop them all on together easily i use this method:
[1] light smear of grease around carb and rubber joints.
[2] small plank of wood fore and aft of a scissor jack.
[3] wind scissor jack open and pop all 3 carbs on at once.
[4] use hardwood. planks protect carbs and frame :D
[5] put engine in first, as per your original post :D :D :D
cheers, dd

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RGT250LC road registered. RG250 gamma engine, Ramair frame.
GT250 big bang road registered. Both pistons fire the same time. USD forks.
GT285 road registered. Overbored - 58mm and TS125 +2 pistons fitted.
GT10 road registered. '65 T10 engine, GT250 frame.


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PostPosted: Sun Jan 28, 2018 5:47 pm 
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Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
Posts: 3145
Location: southwestern Pennsylvania
Country: USA
Bikes owned: 69 T350 thru 75 GT750
I have individual carbs & new boots. So the carbs will be easy to install.
But those tips are useful for future reference incase I need to remove the carbs from my 75 GT550 or red 75 GT750.

_________________
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 73 project
T350 69, 71 & 72 project
T250 72
Honda 85 CB650SC & 86 CB700SC
Yamaha 75 XS650
09 Triumph Bonneville SE


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PostPosted: Sun Jan 28, 2018 7:06 pm 
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World Superbike
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Joined: Thu Feb 16, 2012 11:50 am
Posts: 2107
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
jabcb wrote:
I have individual carbs & new boots. So the carbs will be easy to install.


:lol: :lol: :lol:

You think? :roll:


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PostPosted: Mon Jan 29, 2018 5:22 am 
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Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
Posts: 3145
Location: southwestern Pennsylvania
Country: USA
Bikes owned: 69 T350 thru 75 GT750
Have individual carbs & new stock boots on the GT380 project that we finished last year. The carbs installed easily one at a time without the use of any grease/lube.
The individual carbs can be a PITA to adjust & keep adjusted but they install much easier.

_________________
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 73 project
T350 69, 71 & 72 project
T250 72
Honda 85 CB650SC & 86 CB700SC
Yamaha 75 XS650
09 Triumph Bonneville SE


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PostPosted: Mon Jan 29, 2018 6:58 am 
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World Superbike
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Joined: Thu Feb 16, 2012 11:50 am
Posts: 2107
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
New rubber adaptors really do make a difference. I didn't have any.
It really does wonders for tbe vocabulary. Fortunately I can swear in several languages - one of the benefits of working around the world as an Engineer I suppose......


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PostPosted: Mon Jan 29, 2018 1:50 pm 
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Yeah Man, the Interstate

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 670
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
Alan H wrote:
New rubber adaptors really do make a difference. I didn't have any.
It really does wonders for tbe vocabulary. Fortunately I can swear in several languages - one of the benefits of working around the world as an Engineer I suppose......

Hahaha. Sometimes there are not enough expletives to convey one's emotions when doing mechanical work. Maybe I should be like you and learn a few languages.


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