SUZUKI GS550 Cafe Racer Build [Part 1] - PROBLEMS!

I bought this 1979 Suzuki GS 550 in September 2023 after seeing it for sale on Facebook Marketplace.

Someone has done a really nice job of the initial design, but as it stands today, it has lots of problems!

Over the next few months, I am going to be fully stripping down and rebuilding my Suzuki GS 550 Cafe Racer. I will be documenting every step in detail, with regular video updates. This includes electrics, engine rebuilt, carburettor work, machining new parts, replacing mechanical tacho & speedo with electronic one etc.

In this video I'm going to walk you around the bike and show you the problems I have to fix, including leaking fork seals, lots of alloy polishing, corroded brake calipers, lack of brake hose retainers, poor powder coating on top and bottom yoke, switch cluster hitting left handlebar, no indicators, headlight spacers, speedo not displaying correct speed, poor mounting bracket, fuel tank filler cap corrosion, exhaust leak, oil leaks, rear brake switch not working, rear brake / pedal assembly seized, wiring loom issues, poorly fitting seat cowl, damage to rear frame and ignition switch relocation.

I hope you enjoy this video!

Let me know what you think in the comments!

Don't forget to subscribe and click on the bell if you would like to see more video's for this amazing project.

Suzuki GS 550 (1979) Cafe Racer Project:    • Suzuki GS550 (1979) Cafe Racer Project  

Thanks Ade

Chapters:

00:00 Introduction
00:40 Leaking fork seals
00:56 Fork sliders
01:05 Brake calipers
01:17 Front mudguard bracket
01:29 Brake hose catching rear of front mudguard
01:38 Bottom yoke powder coating and corrosion
01:53 Switch cluster on left handlebar - Motogadget M-Unit - indicators, horn and headlight
02:16 Headlight bracket spacers
02:29 Indicators
02:47 Front brake hose crushed by bottom yoke lock stop
03:02 Switch cluster on left handlebar catching fuel gauge on left side of tank
03:20 Mechanical tachometer, speedometer & mounting bracket
03:46 Filler cap on tank
03:52 Exhaust leak & mismatched bolts
03:59 - Oil leaks
04:16 Left engine cover
04:30 Shift rod
04:42 Rear brake switch - not functioning, mount & wiring
05:20 Carburettors fitted with pod filters
05:30 Rear brake reservoir mounting bracket & leaking fluid
05:52 Rear brake master cylinder / pedal assembly seized
06:00 Ignition switch & wiring
06:15 Left foot peg - frame cut open
06:29 Engine mount
06:40 Original foot pegs
06:51 Seat cowl fitment & damage to paintwork
07:06 Tail tidy and mount
07:24 Seat
07:42 Under the seat cowl - Lithium battery, Motogadget M-Unit, under tray, wiring & frame damage
08:17 Outro

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