550MX help wanted

[MrJDP46_]

Hi,

Bought a 1982 550 MX Katana (mostly) as a box of bits and am trying to return it to the road.

Frame & various parts have been blasted & powder coated, new fork tubes, etc.

I am now trying to reassemble, but it's like trying to build a large LEGO kit without the instructions or parts list!

Fowlers/CMSNL websites and Haynes manual are some help, but what would REALLY be good would be some detailed images of what it SHOULD look like.

That way I can a) see what it should look like built; and b) work out which bits I can't find.

1) rear axle: I suspect I am missing a spacer on one side. Can someone please either share or email a pic of the "correct" way the rear axle should be?
2) Looks like I have two different rear master cylinders (& I think I've had the wrong one refurbished ). What does the correct one look like and where/how does it attach to the frame (rear disk model)?
3) Torque settings for the front/rear axle? In fact, maybe a complete set of torque settings?
4) Engine mounts: how many should there be and what are the specs for the mounting bolts? I think have all the mounts & bolts, but not sure.

Thanks.

james<AT>pettifor<DOT>org<DOT>uk

[fossie]

The Haynes manual that covers gs 550 will show the settings spacers etc. As will the genuine Suzuki one, only a few quid from an eBay seller.
As for master cyl it depends on the year And does it really matter?

[MrJDP46_]

Thanks.

If I could attached photos to the post, I'd show you how the rear axle looks, but doesn't work :@

Added to My Gallery: app.php/gallery/album/19 (hopefully you can see these).

My concern is the sprocket side where there is large "gap".

The disk side looks OK, albeit I am missing the nut. The size of gap looks a bit large to close up by tightening the nut (15-20mm).

[MrJDP46_]

Thanks, Blix.

Maybe I have the spacer on the wrong side?

I have loosely fitted the caliper bracket with a spacer between this and the wheel bearing, but no spacer on the sprocket side.

Maybe there should be another spacer on the sprocket side?

[johnr]

but dont forget that number 5 in the top pic is also a spacer that goes inside the sprocket carrier. miss this one out and you are in for a world of pain, collapsed bearings, broken chains, misalignment etc etc.

[MrJDP46_]

If there’s anyone with a 550 Kat who lives within an hour or so of Ipswich, would it be OK for me to come and see your bike? Would be a real help to see how certain bits “should” be put together and to take some pics of how it ought to look. (The joys of trying to build a kit with no proper instructions...)

Thanks.

[Kryten]

Hi, I don't have a 550 anymore and I live a bit more than an hour from Ipswich but.....

I had my Kat out in the daylight over the weekend and also a spare wheel, spindle, and spacers. Took some photos so will endeavour to post up in the thread this evening.

[Uncle Bob]

There was another newbie with a 550 in Norwich recently:
viewtopic.php?f=8&t=7268 - see Stef-o post. You could try and private message him. If you do come up this way I'm just south of Norwich (Poringland) so you're more than welcome to come and say hello. I can always take the back wheel out of the 1100 Kat for a laugh!

UB

PS best not mention you are in Ipswich after the last local derby if you contact Stef-O !!! I'm from Suffolk originally so will not say anything...

[Kryten]

OK. So it's a 750 and the wheel's a spokey dokey. But it is pretty much what you will have for the 550

Right hand side: Nut-Washer-Chain Adjuster-Swinging arm-Spacer-Caliper Support

Second picture shows "Top Hat" or flanged spacer between Caliper support and hub

[Kryten]

Left Hand Side shows: Spindle Head-Chain Adjuster- Spacer(into Oil Seal)-Sprocket Carrier