Hello Everyone!

Hello Everyone! Intro and Build Thread

Hello everyone, my name is Jeremy (nick name Wally) and from North Dakota. My son had bought a 1980 gs55o Suzuki this winter and have spent the last many weeks getting it running. That sparked my interest in riding again and so when i came across a 1980 xs650 for cheap i decided to start a project. The past owner told me his son had tried several times to get it running with no luck (no spark). I'm not sure the whole story but it looks like he got a hold of an older engine with points and tried to install it in the 80' without understanding the electronics of the situation.

Below is some early pics of the project. i forgot to take a pic of the untouched purchase so my build thread will be incomplete . Oh well i'm sure you all know what a stock 650 special looks like. When i got it home i noticed the engine turned over kind of hard and i couldn't figure out what was going on so i torn it down to check it out. I ended up finding after i had torn the jugs off that there was a screw wedged between the armature and stator alternator. Uggg, i wish i would have torn the charging system apart right away as i would have rather waited with any engine work until after everything was placed, routed, fab complete, and ready to break down for paint.

I have already learned plenty from xs650.com and look forward to any help i can get.

Thanks

Welcome to the site. Now that you have the motor apart. You can freshen up the top end. Valve guide seals and lap in the valves. Front cam chain guide usually needs replaced. Nice project.

huh... I almost baught a gs550 last summer. it only ran on one cylinder. But im sure it had to be a different gs.
Anyways.. welcome. lots to learn here.
hopefully the screw was the only thing wrong with the motor. freshen it up, and run it. see ya 'round.

Hi wally and welcome,
the first thing to do is change out those horrible rototiller 'bars.
Are the rotor & stator still OK or did that trapped fastener wreck them?
The photo shows the rotor still in place; the only way to remove it is with the proper puller.
Well, the only way that won't wreck it further.
MikesXS sells them, they are not expensive.

angus67 said:

huh... I almost baught a gs550 last summer. it only ran on one cylinder. But im sure it had to be a different gs.
Anyways.. welcome. lots to learn here.
hopefully the screw was the only thing wrong with the motor. freshen it up, and run it. see ya 'round.

Click to expand...

newer gs550 are twins and old ones are inline 4.

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Went through the head tonight and everything looks good. New seals on the way with the rest of the gaskets and seals. Plastic was loose on the chain guide so i ordered a new one. the threads on one of the spark plug holes looks as though it had be cross threaded a few times. may have to put in a helicoil . =(

on order, gaskets and seals, carb kits and jets, MK25 hard tail and mono shock seat mount.

CDNTX650 said:

newer gs550 are twins and old ones are inline 4.

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Click to expand...

it was a '85 inline four. I would have baught it, but it was cali plates. they only wanted $500.

Carbs done! 135 mains and 45 pilots, hope that is an ok starting point..
Finish engine on Sunday!

It's not every day you meet a Wally that is into XS650's.

i thought i was the one and only!

Engine back together and back in frame. Weld on the hard tail this weekend if it comes this week

Anyone want to buy these handlebars??

Hell no! Put them on your roto-tiller, and churn up the back forty. They aren't called roto-tillers for nuthin'.

no turning back now so it seams!!

All welded up!!





Seat pan mounted



Back apart, spray can paint job, and back together.

that's a lot of work to be covered with a rattle can. What did you use?

i have quite a bit more to mount. will be blasted and powdered in the end.