GS673 Conversion — Cleaning The Crankcases and Painting Engine.

The 673 kit.

The next step for the GS550 is to relieve the crankcases slightly so that the bigger diameter liners will fit inside. I'd just ordered a new Dremel as my old Draper version was getting a bit tired. That thing has been amazing and I've had it almost twenty years — it's done lots of porting and polishing. Anyway, i was in the process of grinding out some of the casing when the Draper tool finally gave up and spat chunks of plastic out the side. The Dremel came just in time!

If you're wondering about the quality of the deburring tools, sandpaper barrels etc., the Dremel ones are superb! I've always bought the cheaper versions and they wear out in seconds, The Dremel ones are worth the extra cost. 

But on with the job. 

I found it easier to slip the cylinders over the studs, turn the case upside down and mark where the liners were touching. Then remove the cylinders and start grinding. Bit by bit, they went lower and lower.

Suzuki GS550E 673 — Stripping the Engine, Decking the Barrels.

And skim the head!

The next thing on the list was the broken fin on the barrels. I cut out a similar shape from some old aluminium that was lying around, then filed it somewhere near. I wanted the barrels to be hot before welding to avoid cracks etc., so a trip to the oven was in order. Half an hour at 150 Celsius was perfect and the liners slid straight out. This was even better because No.4 sat slightly proud before I started.

Roughly shaped, let's take a look.

Suzuki GS550E — 673 Conversion.

Slight Misfire Halts Play!

It finally happened, I knew the engine was on borrowed time, but it's been happily running me around for the past couple of years, relatively drama free. Now, still running reasonably well considering, it's misfiring on one cylinder and after a quick compression test, no.4 was found to be sadly lacking. You could also hear the familiar chuff-chuff out of the righthand pipe from a burnt exhaust valve.

The reason, you may well ask, why this engine was on borrowed time was because there is wear in the camshaft journals, so not ideal to do a top-end rebuild with the original head. And finding another head for one of these seems to be impossible in Australia. Plenty in the UK and America, but postage wouldn't be worthwhile.

RPM Moto Nerang — New Chain and Sprockets for the GS550E.

Suzuki GS550E — I'm attached to this little bike.
It's nowhere near restored or concourse, and likely never will be, but looks pretty good considering the condition it came to me in. I'm always doing little jobs on it, and enjoy the odd ride out even if the seat is as hard as wood.

The chain and sprockets were well worn, in fact the chain I was using came off my Gixer1000 years ago. So when I saw a NOS standard rear sprocket for next to nothing on eBay, I snapped it up (obviously a fifty tooth sprocket for a GS550 is not a common item now). The gearing on the 550 was way over the top before, and was fitted with a 43T on the back. I'd always thought it had the wrong chain guard on it because of the huge gap underneath, but that wasn't the case. Standard size was seven teeth bigger.

So now I needed a front sprocket and an O-ring chain to go with it. A quick look on eBay and there was a shop selling both, with different sized fronts if need be. I decided to go for a 16T to give the GS a sightly more relaxed time (15T is standard). The prices were superb, and with a little more investigation I found out they were actually on the Gold Coast.

So I popped in...

Suzuki Bandit 1200 — Suspension Upgrades.

The Bandit is pretty damn awesome!
Especially considering, for the last couple of months, the shock absorber has been breathing its last and dumped its oil. Not bad for a 24 year-old bike.
Hustling it along was ok as long as you didn't force it. Maintain pace and keep things smooth and it handled most roads perfectly. But while I've been off for the Christmas break, I figured it was time to sort it all out. With a GSXR1000 K8 shock ready to slot in, it was time to upgrade.

Suzuki Bandit 1200 — Tacho Update!

Resistance is indeed... futile.
As the previous post eluded to, the big Bandit's tachometer is now working only by hooking into the black/yellow coil-feed wire. This is how Suzuki did it on the later Bandits, and I'm having to do this because the later model CDI unit I bought doesn't run a feed to the tachometer. 
After joining the two wires together where the looms plug into the CDI unit, I initially thought my troubles were over, until i hit the 4,000 RPM range.
But then the needle went berserk, floating all over the rev range until you dropped the engine speed to four grand again.

I put this down to interference from the coils, and wondered whether a resistor inline with the tachometer might help.

There were various performance shops around the world selling such items for race cars so, with a bit of shopping around, found that a 10,000 ohm resistor was the way forward. Worth a punt for a few cents (unless you find the guy on eBay who was trying to sell them for $16 per resistor! 😐).

I bought a pack of 25 for $5.82 😀 (you never know when you might need another).

Mk1 Suzuki Bandit 1200 — Tacho Not Working!

Comfort.
I think I've been cramped up on sports bikes too long, because I absolutely love the comfort of the GSF1200! Just this Sunday, after a bacon and egg roll and flat white at Cafe Metz, I headed up the Goat Track. For those not in the know, it's a cracking little road full of hairpin bends that takes you up to North Tamborine. Great fun, up or down, whatever bike. 
Fifty K's per hour is how fast I was going. Fifty K's! 
I was more mellow than a bong-induced mellow guy from Mellowford, and happy to cruise. Until six or seven bikes flew past me like I was on a pushbike!
I took chase, but gave up when the front got a bit iffy in one of the bends. All good, back to Sunday morning cruising.

So what's this thing like day-to-day?
Honestly, it's blown me away. It's quick when you want it, happy to mooch around at snail's pace, just a cracking allrounder. I'm fixing up little things as I go, and making a list of things I want to do.

One thing that was niggling me since getting this thing running was the rev-counter... it wasn't counting the revs. I had two secondhand CDI units, it didn't work on either. I had continuity from the tacho (black/red), back to the CDI. I had 12v and a good earth at the tacho itself. So the tacho must be faulty? One would assume so. But to assume... 

New Old Stock.
Secondhand rev-counters were going for around $150 on eBay, if you could find them. But then a NOS one came up for $300.