MARTYN PITCHER’S SUZUKI GSX550 ESD

In 1985 I purchased a new white and blue GSX550ESD (C120 GEV) from Reg Miller Motorcycles in Colchester. Over 30 years later, while looking at a photo of that very bike, I decided that the model would be an ideal subject for a project.

I purchased this bike on ebay in 2016 with rose-tinted glasses. I had been searching for some time, but was unable to find a complete working bike. This one had covered 63k miles, but was a UK bike with a running engine and current MOT. Following a 360-mile round trip to collect it (thanks to brother Nick for transport), once home, the bike was washed and completely stripped down to frame, wheels and engine. There were incorrect fittings, wiring damage, component damage, bodywork beyond repair and more. The initial intention was not to strip the engine, but when preparing to replace a leaky head gasket it became clear from the goo on top of the pistons that this bike was worn out.

The engineg was completelypy strippedtripped and inspected. When the sump was removed the primary strainer was about 80% blocked with debris, so stripping the engine was definitely the right action. Amazingly, the crankshaft and piston bores were all well within factory tolerances. New bearing shells, cam-chain, pistons, rings, pins, clutch and valve seals were all fitted.

I decided to restore the colour scheme to my original white and blue. To be consistent, the anti-dive system needed to be retro fitted to the earlier linked design instead of the Posi-damp version installed on this 1986 model. I painted most of the small parts myself while the frame, engine and tank were professionally painted. The spindles and suspension fixings were all re- plated, forks re-chromed by AM Philpot, and the screen was made by Skidmarx. Thanks to Jim Mcmanus for the engine strip, re-build, final carb set up and valuable advice. The restoration took twoand-a-half years. It was a challenge, but the result is a joy to ride.