Suzuki GS 500 E - Time to overhaul it! *Pics added*

[Bishbash]

OK, it was time to upgrade my bike as it just isn't gutsy enough for longer journeys, so I bought a GS 500 last night off of flea bay. Pick it up Saturday, so I am getting quite excited. All it needs is a new battery, tax & MOT and I'm off on it. Here is a couple of pics;

https://i142.photobucket.com/albums/r94/Neileng/gs.jpg
https://i142.photobucket.com/albums/r94/Neileng/gs1.jpg


So now I have 7 bikes in the garage and it is time to sell 1 or 2 to make room. So the GPZ 305 is out and I will pick another one. I will sell that for £300 or something silly as I just want rid of it. That is all taxed MOT'ed etc runs well, new tyres and I recently serviced it all, so I should get that easy. I hope.
____________________
My current bikes are - YZF-R1 & GS 500 E

Trackday videos - https://www.youtube.com/user/bishbash13

[chris-red]

If you need any parts I have half of one sitting in my garden, I have 2 wheels with good bt45s on if you need tires.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Bishbash]

Ahh, cheers buddy, I will PM you if I find anything that needs replacing, it has brand new tyres and it just needs the battery replacing. Other than that I dont know yet.

Thanks for the offer.
____________________
My current bikes are - YZF-R1 & GS 500 E

Trackday videos - https://www.youtube.com/user/bishbash13

[Gazdaman]

If you want a powder coated frame and swing arm, there's some in my room

Gaz

[Thom]

I have a GS500 project lined up as soon as i can find a suitable shitter as the chosen bike!

I quite want an '89 but im after anything.

Headlight – Undecided
Front End – ZXR400 USD or Marzocchi forks + vfr400/duke front wheel.
Engine – Ignition advancer, K&N Air filters, Up jet Carb
Exhaust – Titanium or stainless downpipes and midpipes, twin underseat carbon cans
Seat Unit – Something square and from the 90's to flow with the bikes lines. CBR maybe, although im considering an RGV.
Rear Shock – Fully adjustable Ohlins item
Rear Swingarm + Wheel – VFR400 (But i'd like a duke rear if i can find one cheap)

Clip-ons, Raised rear end, Rear sets, digi speedo+clocks etc.
____________________
Current Bike: 1996 Yamaha TRX850 (The Japanese-Ducati One).
Previous Bikes: 1990 Honda NSR125 'Rothmans' (The smoking one), 1990 Suzuki GS500e 'Caf? fighter' (The loud one), 1987 Kawasaki GPX400r (The quick one), 1997 XJ600s Diversion (The reliable one), 2000 Kawasaki ER-5 (The spontaneously combustive one)

[Bishbash]

Wednesday

Right So I had an hour before my Mrs arrived so I thought I'd make a start. I wiped off the front caliper cleaned it up and made sure all the pistons and seals were ok, and they were.

That did not take long so I also discovered the horn was covered in rust, so off it came and rubbed down and painted.

Hour is up, she arrived.

Thursday

So the Mrs has fooked off to Ireland for 5 days leaving me in peace. So, on goes a Nickleback album and crack open a bottle of Scotch.

Rear caliper off, I discovered the pins were highly corroded so I could not take the pads out to check the pistons. I had to split the caliper, everything was ok. Cleaned the caliper up with old brake fluid and it came up a treat. So both calipers ready to go back on the bike.

https://i142.photobucket.com/albums/r94/Neileng/calipers.jpg

Here it is, the first problem. I wanted to take the exhaust off to rub down and horse some Hammerite BBQ paint all over it. As you can see it is a little rusty.

https://i142.photobucket.com/albums/r94/Neileng/downP.jpg

So, I began to take it off and on the manifold there are 2 bolts, one is a bolt and the other is an alan key bolt. I managed to snap the alan key I was using, it was that corroded . So any ideas to get these bolts off? I am not keen on an impact driver, as I am usure if it could damage the engine. Any ideas welcome. Or if you can use an impactdriver, let me know.


So, putting the exhaust aside for now. I took the rear wheel off and cleaned it all up, took the sprocket off cleaned that up and greased up the bearings.

https://i142.photobucket.com/albums/r94/Neileng/dcd.jpg

And after I was done with it;


https://i142.photobucket.com/albums/r94/Neileng/ccd.jpg

Rear wheel is ok apart from a rusty brake disk. But that will polish off under breaking.


Whilst the wheel was off I took a look at the swing arm and it was not nice.

https://i142.photobucket.com/albums/r94/Neileng/dsa.jpg


So cleaned it up, rubbed it down and spray painted it from a rattle can. It came up a treat.


https://i142.photobucket.com/albums/r94/Neileng/csa.jpg


Getting late now(1 am) so time to finish. Calipers back on and grease a few bits up and clean the chain, then threw it in a load of oil to really soak. Also stuck the battery on an overnight charge.

And for tonight I did not do a lot to it, just a few more coats of paint on the swing arm and that was about it. Lazy day....
____________________
My current bikes are - YZF-R1 & GS 500 E

Trackday videos - https://www.youtube.com/user/bishbash13

[chris-red]

Buy a stronger/decent allen key and put an extender bar over it. Cover it in wd40 too. You could also shave off the sides and put a spanner over it, I would only do that if you have a knackered head though.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Bishbash]

The head is fine, I will try the impact driver tonight and see if that will loosen it a little. Then, if I can get it off it will look mint.
____________________
My current bikes are - YZF-R1 & GS 500 E

Trackday videos - https://www.youtube.com/user/bishbash13

[Gazdaman]

Impact driver'll be fine to use. But yeah, use some penetrating oil, and some heat too.

Gaz

[Bishbash]

quick update, the rear wheel I re-assembled and tried to get the exhausts off, no joy

I will just tape everything up, and repaint them on the bike.

Also I was looking at the rear(new) tyre and it has cracks in the tyre wall, so that needs to be changed, extra £60 I could have saved.

Oh well!
____________________
My current bikes are - YZF-R1 & GS 500 E

Trackday videos - https://www.youtube.com/user/bishbash13

[L-Jam]

Any updates Bishbash?

I bought a 1997 GS 500 today for 750, 20,000 miles and nothing wrong with it, but I'm looking for an excuse to Fuck about with it haha
____________________
Journalist, student, egotist.
Click here if you're a young biker, wondering what to do after a moped/125!
Skp 50 --> GS 500 --> CBR600F with custom HRC paint jobby --> GSX-R 750 K7, beautiful!

[Thom]

i want my GS back
____________________
Current Bike: 1996 Yamaha TRX850 (The Japanese-Ducati One).
Previous Bikes: 1990 Honda NSR125 'Rothmans' (The smoking one), 1990 Suzuki GS500e 'Caf? fighter' (The loud one), 1987 Kawasaki GPX400r (The quick one), 1997 XJ600s Diversion (The reliable one), 2000 Kawasaki ER-5 (The spontaneously combustive one)

[Gazdaman]

Someone buy the damn powdercoated frame and swingarm that's hanging in my garage!

Gaz

[L-Jam]

How much Gaz ? haha
____________________
Journalist, student, egotist.
Click here if you're a young biker, wondering what to do after a moped/125!
Skp 50 --> GS 500 --> CBR600F with custom HRC paint jobby --> GSX-R 750 K7, beautiful!

[Gazdaman]

Gimme £30 and pick it up and you can have the bastard lot.

Gaz

[Bishbash]

[L-Jam]