Suzuki GT550A rebuild

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Suzuki GT550A rebuild

Post by Alan H on Fri Dec 19, 2014 11:02 am

More details HERE (clicky).
Just got the frame and most of the black bits back from the powder coaters, so I know what I will be doing over Chrimbo now at least!!

Bought another (Clicky cos I can't post pics) one a few weeks ago, and the engine will go into the J (only 14 numbers away from what it was originally!!), and the forks and some other bits will go on the A to save some work. Hopefully I will have a choice of 550s to go to the IOM on for the Classic TT in August next year.
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Wed Dec 24, 2014 2:22 am

Nice one Al.

Bollocks I cant stop this!
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Re: Suzuki GT550A rebuild

Post by Alan H on Fri Apr 24, 2015 4:58 pm

Just got the paintwork back, so pics HERE for anyone interested. Hopefully engine back in this week and I can work on getting it all back together and running again in the not too distant future.
Colour is black with red metallic flakes which look really good in sunlight.
Wheels are GS550 and the GS swing arm fit straight in. The rear master cylinder isn't as straightforward but should be sorted pretty soon.

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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Sat Apr 25, 2015 2:49 am

Looking pretty

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Re: Suzuki GT550A rebuild

Post by Alan H on Sun May 10, 2015 4:20 am

More updates on the links earlier. Hopefully this will be all done by the end of July so I can get some miles on it before the Classic TT at the end of August. If not, then the green GT550K will be going!!
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Mon May 11, 2015 11:48 pm

Fingers crossed

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Re: Suzuki GT550A rebuild

Post by Alan H on Thu Jun 11, 2015 2:50 pm

The rebuild is still progressing and just got the 3-1 back from the ceramic coaters. Hopefully get it fitted thie weekend and might get the rear brake working after farting about with the master cylinder again. More details at the original link.
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Sat Jun 13, 2015 6:53 am

Lol, you'll do it

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Re: Suzuki GT550A rebuild

Post by Alan H on Mon Nov 02, 2015 10:16 am

Just to show I'm still making some progress.
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Tue Nov 03, 2015 12:17 am

Looking good there, very good. I am envious

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Re: Suzuki GT550A rebuild

Post by Alan H on Sun Mar 20, 2016 10:47 am

The build up has been slow recently due to me having a 5 week holiday in Hong Kong, Australia, New Zealand, Viet Nam and Hong Kong again. Back home yesterday and my brain doesn't know whether it's light nights or dark days yet what with all the time zones we did.

Anyway, more details on the first link, I had a set of spannies made while I've been away, and can't wait to get the bike home and see what they are really like.
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Re: Suzuki GT550A rebuild

Post by Alan H on Tue Mar 22, 2016 11:24 am

Coming on now!!
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Wed Mar 23, 2016 8:29 pm

Really hate you

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Re: Suzuki GT550A rebuild

Post by Alan H on Thu Mar 24, 2016 2:59 am

Oh and there's another 3.5 550s here as well.
Just thought you should know that. Laughing
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Re: Suzuki GT550A rebuild

Post by Alan H on Sat Apr 02, 2016 1:16 pm

Hahahaaaaaaaa!!!!!!!
It's alive!!!!!!!!!!

Some poor connections on what appeared to be a good harness, so just frigged the wiring to get power to the coils, filled the carbs, a tiny squirt of easy start and went FIRST KICK! (No lecky start working due to solenoid problem).
And now ticks over. Sounds lovely with the spannies too.

Woo bleedin' Hoo!!!!

And today, tried it on our street - no tank, wiring 'not complete!' etc. Ran fine and when I cracked the throttle for the return run, popped a wheely-ette. Now I know it's easier without a tank and other bits at the front end, but I've always had to work the old 550 to get the front wheel up, so to say I'm chuffed is a fair understatement!
Looks like Mr. Abbey (the spanny man) has done good.
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Sun May 22, 2016 10:54 pm

Nice one, you sexy beast

Bollocks I cant stop this!
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Re: Suzuki GT550A rebuild

Post by Alan H on Mon May 23, 2016 1:42 am

The bike's nice too, I think. I love you
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Thu May 26, 2016 11:56 pm

What are the wheels from? Look like GSX 250 type thingys

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Re: Suzuki GT550A rebuild

Post by Alan H on Tue May 31, 2016 10:48 am

GS550, Bill.
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Re: Suzuki GT550A rebuild

Post by Alan H on Tue May 31, 2016 10:48 am

More details on the original link in post 1 on this thread.

Been 'fettling over the last week or so and got lots of jobs done. Mounted the Vapor dash on a bodged redesigned bracket which looks awful (at the moment) and carries the ignition switch. Needs to be a bit thinner and better - this will be done 'soon'. (TWBDS)
So, the speedo works, the revcounter does what it wants, so needs sorting - maybe. (TWBDS)
The front brake was just dragging, but needed running a bit, so hopefully this will turn out OK.
Lights working, had to fit the original headlight (rechromed) as there wasn't enough room in the one I had painted due to all the wiring.
Fitted airhorns OK.
Lekky start working and found a missing bleed screw in the left carb, fited a plug in it, must check if it should be an adjuster! (TWBDS)
Painted a plastic chainguard and cut a coup-le of pieces of strap to mount it. Paint still wet and it needs some rubbing down anyway. (TWBDS)
Did you know that a road bike needs a chainguard when it's actually running on the road, but doesn't need one for MOT? Neither did I.
Anyway, went for MOT today and he marked the chain as advisory - not chainguard, chain. Oh well.
Other than that passed OK. A couple of bits to do as 'recommended' and what I've noted needs doing after the shakedown run, but as this was the first proper run in 31 years (going by the last tax disc which ran out in June 1985) I'm not too concerned. Nipped to the PO and taxed it - £33 for 6 months (registered in April '76) and free from next year.
How did it go?
Well, I took it steady down our estate and onto the main road, up to the first roundabout and onto the relief road. gave it a bit of beans and at about 5K, it set off like the clappers. A real kick and a noticeable powerband (and a gert cloud of blue behind!!).
Never had that on a 550 before - powerband that is.
Kept it down to 'about' 60 and ran well to the MOT place and back. Much crisper and quicker than the Green J, so whether that's down to the later barrels with Schneurle ports, skimmed head, suspected porting work and/or the new spannies, I can't be sure. Can't wait for a fine day and a few more miles under the Dunlops to see what it really goes like.
Happy? Not chuffin' much! What's not to be happy about with 2 GT550s running.









Just realised, taxed it today almost exactly 31 years to the day the last tax ran out!
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Sun Jun 05, 2016 9:30 pm

Sweet! Don't forget to do some plug chops to get the jetting spot on with the spannies and other possible work.

Bollocks I cant stop this!
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Re: Suzuki GT550A rebuild

Post by Alan H on Wed Aug 24, 2016 5:16 pm

Runs fine now after a few issues with slipping clutch (now sorted hopefully) and now with the spannies ceramic coated by CamCoat - in Cermakrome ( http://www.camcoat.com/main/coatings6.html )


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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Mon Aug 29, 2016 12:27 am

How much does the coating cost?

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Re: Suzuki GT550A rebuild

Post by Alan H on Tue Aug 30, 2016 2:15 am

3 spannies, 3 downpipes and 3 screw clamps , £200 + vat.
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Re: Suzuki GT550A rebuild

Post by Bill (the boss) on Wed Aug 31, 2016 5:49 am

Not too shabby

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Re: Suzuki GT550A rebuild

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