SuzukiSavage.com - Project bike almost done

thomasoconnor19

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Project bike almost done
06/21/13 at 14:12:42

My 03 Suzuki project is very close to being finished. Took a while but I am very happy so far. Used a Ryca tail/seat and a Suzuki GT550 tank. The GT550 tank is a little longer than the Ryca tank so I had to cut a bit of the tail and seat...I like how it looks a little shorter too.

I have a Kenda K761 130/80-18 tire on the way which will really make the stance look a lot better I think. Currently it has a 110/80-18 which I felt was too small.

I used Plastidip spray to paint the tank and seat and am pretty happy with the results. Its smooth but it doesn't feel like real paint. The great thing about it is that you can just peel it off.

I built my own emblems up in CAD and am going to CNC them next week. Going to leave them raw, or paint them black and sand the top surface so part of the aluminum is exposed.

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scannerzer YaBB Newbies Offline I love YaBB 1G - SP1! Posts: 31 northern ireland Gender:	Re: Project bike almost done Reply #1 - 06/21/13 at 14:29:07 love the emblems
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thomasoconnor19 Full Member Offline SuzukiSavage.com Rocks! Posts: 147	Re: Project bike almost done Reply #2 - 06/21/13 at 23:23:50 Here's a photoshop of a larger rear tire and how it should look once its all finished. Right now I'm having trouble getting the 2 bolts installed that hold the seat pan and tank down. The longer GT550 tank leaves me with a very tight area to access the top of the bolts.
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ToesNose Serious Thumper Offline Pardon me, do you have Hot Sauce? Posts: 1993 Mooresville, NC Gender:	Re: Project bike almost done Reply #3 - 06/22/13 at 04:21:22 Looks like things are coming along nicely The tank emblems are a very cool personal touch!
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17821 Camp Springs, Kentucky Gender:	Re: Project bike almost done Reply #4 - 06/22/13 at 05:41:20 Your tank is back a bit farther than mine.....I can see how you would have a difficult time getting to them. Maybe you could weld nuts on the top of the seat pan, drill out the stock thread in the original mount, and then have the bolts install from the bottom just above the carb inlet.
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thomasoconnor19 Full Member Offline SuzukiSavage.com Rocks! Posts: 147	Re: Project bike almost done Reply #5 - 06/24/13 at 16:59:53 I ended up being easily able to drill the holes in the frame out and then sticking a bolt up and getting the nut on by hand. Before with the bolt threaded through the frame, it was much harder to get the nut on as you couldn't easily move the bolt.
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thomasoconnor19 Full Member Offline SuzukiSavage.com Rocks! Posts: 147	Re: Project bike almost done Reply #6 - 06/25/13 at 19:25:39 Put some gas in the tank for the first time and now I see that my petcock leaks a lot. Hopefully a rebuild kit fixes this!
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ToesNose Serious Thumper Offline Pardon me, do you have Hot Sauce? Posts: 1993 Mooresville, NC Gender:	Re: Project bike almost done Reply #7 - 06/26/13 at 04:38:23 Yikes!!! That is a lot
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thomasoconnor19 Full Member Offline SuzukiSavage.com Rocks! Posts: 147	Re: Project bike almost done Reply #8 - 06/26/13 at 18:25:01 Yah I'm hoping a rebuild kit fixes it. Got the tank/petcock off of eBay and it wasn't leaking when I got it. It came with nasty gas in it. I took the petcock apart a while ago just to clean all the crud out and am pretty sure I put it all back together right. Maybe cleaning all the junk out of it opened up a new leak?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Project bike almost done Reply #9 - 06/26/13 at 22:41:09 It came with nasty gas in it. thyey FREIGHTED old gas? doooooh!
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thomasoconnor19 Full Member Offline SuzukiSavage.com Rocks! Posts: 147	Re: Project bike almost done Reply #10 - 06/26/13 at 22:58:02 Right?! Suprised the guy didn't empty it out first out of common sense and to save on shipping costs too.
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thomasoconnor19 Full Member Offline SuzukiSavage.com Rocks! Posts: 147	Re: Project bike almost done Reply #11 - 06/27/13 at 23:13:00 Would anyone happen to have a manual/parts drawing for the gt550 petcock? Just want to make sure that I put this thing back together right or I'm not missing any parts. Hopefully the new rebuild kit will fix this leak problem.
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gdrseeker Senior Member Offline Addicted!! Posts: 365 Carson Valley NV	Re: Project bike almost done Reply #12 - 06/28/13 at 15:34:54 Inside the Petcock?
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thomasoconnor19

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Re: Project bike almost done
Reply #13 - 06/29/13 at 13:25:49

I got another petcock rebuild today and its the one for 75 and earlier gt's. the 4 hole seal is 25 mm, mine is 30 mm.

The 75 and later kit I bought has the 30 mm 4 hole seal which fits my petcock....but it also came with 2 of the gaskets for the spacer between the tank/petcock which my tank did not come with. Those gaskets in both kits don't seem to fit anyways...they're longer than mine and have a circular profile where mine is square.

Still getting a big leak from the fuel selector even after I replaced the 4 hole seal. Am I missing a part? I have the 4 hole seal, this thin metal crush washer, then the fuel selector part.

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thomasoconnor19 Full Member Offline SuzukiSavage.com Rocks! Posts: 147	Re: Project bike almost done Reply #14 - 06/29/13 at 13:26:37 Anything missing?
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