Gs500 rebuild *tuptdate*

[dransy]

In a spur of a moment decision i thought to myself that looks abit shit! , i know what ill strip it down respray everything black should be done within a week.

So here we are 4 years later!!!

https://www.bikechatforums.com/files/imag0007.jpg

This is how the old girl stood on saturday basically shes been like that for nearly 4 years ive got no pictures of what i did 4 years ago so ill just have to update from what i do from now on.

I have 3 engines in my garage , engine no1 flywheel thread is shagged , engine number 2 bottom end has gone engine number 3 the dreaded front mounting bolt seized!

After a long time trying to get this bitch of a bolt out i finally got it out by grinding of both sides and drilling through!

So sunday time for me to get of my ass and put my engine in!

https://www.bikechatforums.com/files/imag0008_170.jpg

Jacking things up with car and bike wheels as i dont have a jack

https://www.bikechatforums.com/files/imag0010_133.jpg

As you can see this clearly wasnt working so i try again ,been a dick and not just going out and getting a jack i tried this method.

https://www.bikechatforums.com/files/imag0011_214.jpg

Yes that is a top of a table with my back wheel of , why? it was worth a try at the time!!

This wasnt working either!

https://www.bikechatforums.com/files/imag0012_749.jpg

So wheel back on table on floor and that big thing is the spare back for our leather recliner oh if the missus saw me do that she would have twatted me!!

Anyway believe it or not this actually got it majorly close! but not close enough.

https://www.bikechatforums.com/files/imag0013_196.jpg

This was my last attempt with bits of wood but yet again it failed.

So i decided to go out and get a jack with wheels!!

Ive got the engine in but it got dark and i couldnt take any pics

But after 4 years im finally getting somewhere

Ill keep updating every weekend as my garage has no power so i cant work during the week.

Im basically keeping it standard except for im going to fit an sv650 rear shock as it will jack the back end up around 2 inch, also i MIGHT fit a katana rear wheel but im undecided on that yet.
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Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[swiftb]

Keep it coming, no wonder you didnt get far in four years - it took you a whole day to accept defeat and buy a jack!

[Dazbo666]

I still have fond memories of the GS500 - if only because it's the bike I used for my DAS and passed my test on.
Plus, I enjoy watching overhauls and rebuilds etc
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1st bike (Sept'06 - May'10) : 1991 GPZ500S / Current bike (since Nov 2009) : 2003 Suzuki Bandit 600N
Word of the day : DILLIGAF

[ORourke]

Good luck, I'll be watching this thread.

[.Bishbash.]

shame you didn't have a before picture, well will keep an eye out to see the wonderful improvements you make
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Current bike - GSX-R1000 k8

[dransy]

[.Bishbash.]

OMG, no wonder you wanted to redo the bike, such a dreadful colour!

Keep on the updates!
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Current bike - GSX-R1000 k8

[dransy]

Bit of an update , I have ELECTRICITY in my garage and its amazing!

Now i can work on the bike when i want to and not when i have to!
Another cool point is my wireless reaches my garage

Dont really no where to start so its most likely going to be a load of jumbled crap but here we go

I found my battery box!

https://www.bikechatforums.com/files/batbox.jpg

https://www.bikechatforums.com/files/batbox2.jpg

urgh ugly

So if i went to bnq n grabbed myself a wire brush and a drill attatchment

and vala

https://www.bikechatforums.com/files/batboxd1.jpg

https://www.bikechatforums.com/files/batboxd.jpg

Might not be amazing but compared to what it was its shed loads better
Now I was having some major ass problems with my wiring loom what a total ball ache!

As i didnt know where anything went i had to go by what few pictures i could find online .

to start of I had to get all this into the headlight. I figured id work from the front to the back

https://www.bikechatforums.com/files/loom3.jpg

After many attempts and i mean many i got it right ! but then realized my headlight was on upside down!!

https://www.bikechatforums.com/files/light_lom.jpg

So i routed it all to the back not correctly in place just a rough idea to figure out where it all goes. Now i thought id crack on with getting my airbox on.

https://www.bikechatforums.com/files/lolops.jpg

The airbox only went on one way *obviously* but then my tank woudnt sit properly so i lit a fag and had a cuppa while scratching my head.

Now i dont know if any of you can see something missing from that picture but it took me a good 20mins , untill i looked on my bench to see my carbs sitting there!!!

What a cock !

My garage is an absaloute shit tip! this is the only floor space ive got but i was plodding on.

https://www.bikechatforums.com/files/workspace.jpg

So i called it a night, and come this weekend just gone the sun was cracking its flags on saturday so i thought id take her out onto the drive to work .

I popped my carbs on but now i cant get the airbox on its been a little bitch .

So instead of getting thrustrated i thought id put the tank and pannels on etc just for the sake of it.

https://www.bikechatforums.com/files/gsnearly.jpg
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Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[dransy]

.
https://www.bikechatforums.com/files/side_180.jpg

A couple of pics without the panels
As you can seen the wiring loom looks abit of a shambles but as far as im aware its correctly routed i just need to tidy it up and clip it the frame.

https://www.bikechatforums.com/files/neked.jpg

https://www.bikechatforums.com/files/neked2.jpg

I need to wait till it gets a little bit warmer to spray my tank , panels any my fork bottoms.

Ive found some brand new brake pads in the garage and also 2 unused front tires Also a brand new chain but i think it may be too small.

Also every single nut and bolt that was on the bike is like my battery box so ive got most of them soaking in an oil bath.

I think from now on im just going to try to get it to look at least half decent! as i want it on the road before summer also i still havent done my fecking test so im saving up for that .

I have loads of parts , nuts and bolts in the garage so i should be alright.!

The only one major problem i have is that i bought the engine second hand and were the downpipes get bolted on one of the nuts is sheared of so im gonna have to try get that out.

Other than that by the looks of it at the moment it should all just be quite simple little jobs. But nothing is ever simple when it comes to a GS!!
____________________
Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[Gazdaman]

How the HELL did you put the airbox on without the carbs,...surely they had nothing to attach to and therefore were just sort of sitting there?

I'm sure there's an amusing internet funny photo that would adequately sum that up. But I don't know it.

Gaz

[dransy]

Well excuse me not updated i turned into a lazy fucking xbox geek!

Anyway got my ass in gear and in the past2-3 week ive done fuckloads!

Managed to take pics along with it too so itll be quite along write up over a couple of posts!

Basically ive took my bike up to my friends garage because his garage is mahoosive! and he basically has every tool i the world!


I ripped out my wiring loom again and totally gutted it replaced a hell of a lot of cabled and basically re-solder half the loom as it was in one hell of a state!!

Figured id try get it started first of all as i didnt even know if the engine ran!

We roughly wired everything up put the carbs on , battery on , bit of fuel in a washing up liquid bottle , my hopes where high

https://www.youtube.com/watch?v=DuvcR9ps7tE&list=UU6QS57rECAYhpkCRaYN5LsQ&index=7&feature=plcp

we tried everything we could of , the bike was blasting shit out of the pipes and backfiring through the carbs,

I put a post in the workshop section , stripped my carbs down and.....

https://www.bikechatforums.com/files/gscarbbad.jpg

poorly poorly diagrham!!

We stripped the entire carbs and replaced the diagrham of a spare set of carbs and soacked/cleaned everything in gunwash!
Still the bike did exactly the same , back on bcf i came i was advised to check the timing but i didnt have a clue at all what to do!
so we left it for the night

Came back 2 days later scratching our heads but refreshed we took the right hand engine casing of with that timing thing in! (i reallydont know what its called) and loan be hold it was foobard it wasnt even in tight , to make it worse it had muched all the screws to pieces!! i thought you FU&%&%& CU^%

Cleaned it all the best i could got some replacement screws , and oh YEAH!!! the little piece of loose fuxing thing was the problem all the time !!

https://www.youtube.com/watch?v=dinnacPC4rU&list=UU6QS57rECAYhpkCRaYN5LsQ&index=1&feature=plcp

5 years it had been stood so i was quite pride of myself as im a little bit retarted
____________________
Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[N cee thirty]

love that vid

Fukin get inn
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'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[dransy]

So after the engine was running carbs got covered up, battery was taken out , wiring loom back of . I got the idea in my head i wanted to do something else to it.... I didnt like the undertray anyway big ugly massive plastic piece of shite the size of farking wagon!

My mate had some spare checker plate that hed removed from his landy! So i decided to make my own undertray! i didnt get many picks of work in progress so to speak so its more or less the finished item without paint etc!

Anyway sorry for no pics in prgress
heres a pic from side/above

https://www.bikechatforums.com/files/und1.jpg

held on the bike by hand

https://www.bikechatforums.com/files/und_2.jpg

How it sat at the back

https://www.bikechatforums.com/files/und3.jpg

Just didnt look right so i decided to chop a bit of the subframe

Before

https://www.bikechatforums.com/files/und4.jpg

After

https://www.bikechatforums.com/files/subchop.jpg
____________________
Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[dransy]

Well we pretty much got it to fit spot on had to alter the bends a little jiggle it about and grind it down in places , so it was time for the brackets . All i did here was grab some steel plate cut it to the right size to fit inside the rear subframe and weld in 2 pieces , one toward the front and one toward the back.

Right down at the front where it curls under the battery back we just drilled it so it can bolted into the same holes the battery box uses

Pics of the brackets

https://www.bikechatforums.com/files/bracket1.jpg

https://www.bikechatforums.com/files/bracket2.jpg

Inbetween taking it turns at jobs etc i got a little bit bored so i pulled out my marker pen and my front guard ... and my angle grinder

i dont know why but i think it looks pretty cool got the idea from someone from bcf a couple of weeks back!

https://www.bikechatforums.com/files/mud1.jpg

https://www.bikechatforums.com/files/mud2.jpg

https://www.bikechatforums.com/files/mud3.jpg

I dont know what it will be like with the mot? but its cool
____________________
Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[dransy]

Well with me chopping pieces from the subframe cutting of brackets on the subframe and battery box making my own undertray and cutting my mudguard i felt like i was on a roll i finally had decent motivation so obviously i couldnt stop there !!

Now dont get me wrong i know this project wont appeal to many people , lets face it , its a gs500! not known for anything fancy , not fast , not good looking basically its a turd!! And we all know you cant polish a turd!

Well its MY turd so im trying to fecking polish it

I thought the origianl undertray was crap so i made my own! well i also think/though that rear/side fairing strips look a cunt! So i got my checker plate out again

Made a template out of some cardboard put it on the checker plate and made this!

https://www.bikechatforums.com/files/rough1.jpg
Just a rough idea of what i was aiming for!

Hmm i seem to have lost the photo from side so ill just have to use this one , i trimmed it up , twatted it with the hammer , ALOT

https://www.bikechatforums.com/files/left.jpg

Basically did the same for the right one which has better pics

https://www.bikechatforums.com/files/right.jpg
https://www.bikechatforums.com/files/right_2.jpg
https://www.bikechatforums.com/files/right_again.jpg

https://www.bikechatforums.com/files/right_back.jpg

https://www.bikechatforums.com/files/bottom_130.jpg

shot with the undertray and the sides curling round to join it

https://www.bikechatforums.com/files/back_793.jpg
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Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[dransy]

OH also! by the way the last picture , NO my subframe isnt twisted my wheel isnt on propperly
____________________
Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[dransy]

Could anyone tell me if I get a k&n lunchbbox or cone filters will I have to get my carbs rejetted?

I really could do with the room where the air box is as I need to put some parts of the loom there .

Cheers
Marco
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Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles

[orac]

https://gstwin.com/
should have most the info you need, the general rule is add 10%. if your gonna do the pilots (i would suggest you do if you havent already) your local dealer may not stock them, i got mine from straightline racing. some people also stick a washer under the needle clip to raise it half a mark. obviously check the sizes against the original to ensure you arent gonna go too far (in particular with the pilots)

alos you may like to do the 5 degree ignition advance, i modded the pickup plate
https://gstwin.com/diy_timing_advance.htm

once you got the thing up and running and on the road (presuming you dont have a rolling road in garage) you will have to hot plug it to tweak the jets till they are just right.

to hot plug, go for a ride with you plug spanner i your pocket, get the thing working hard (and hot) keeping the revs up, while they are up hit the kill switch (this may scare the sh*t outta ya) while pulling the clutch in and coast into a lay by (do it near a layby is best), whip the plugs out and check the colour. then adjust mixture with either the mixture screw (for fine adjustment) or most likely the main jet, start with 10% over or under where you started (dpending on colour) - rinse and repaeat.
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Current rides - 2016 Triumph Street Triple Rx, 1994 Suzuki Bandit 400 VM, TGB 204 Classic 125cc
"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"