Full Rebuild of a 91 GS

[rubberpenguin16]

Im new to the site but i wanted to share what im doing and maybe get some ideas from people that have worked with the gs more before i get into the reassembly part of the project

Im rebuilding a 1991 GS500E that i got from a guy who used to run a shop. it needed a new cam chain and blades when he got it and the kid decided he didnt want to pay for it so he just dumped the bike with him no title or anything. it sat in a barn on its side for about 8 or 9 years after that  with the head and block removed.

now that i have it i found the engine is pretty much beyond help... one of the pistons broke the tang off on the bottom and the rods are rusted almost all the way through. mice have found it a nice home and the acidity of their excrement has eaten away at most of the transmission gearing. basically i need a whole new engine now as its not practical to purchase the new parts i need for it... i can get an engine in better shape and just replace common bearings and seals for less than half the price.

Aside from that the keys were lost so i need an ignition switch, gas cap, side seat lock, etc. etc. the front light was changed so an aftermarket windscreen could be put on. i hate the windscreen and without it the light is a big square black blob. i would like to find the original pieces and mounts to correct this.

i am almost done with the rewiring of most of the critical components and after that its just going to be touch and go from there.

any parts, suggestions, advice, opinions... all are welcome.

[Phaedrus]

This sounds like a really fun project. The GS is great for this kind of project because there is such a great community (here!), and parts are usually cheap and easy to find.

Good luck and be sure to take a lot of photos! Especially "before" and 'after" type stuff. And if you get an engine and rebuild it, I am sure folks would appreciate photos and tips on that as well.  

[that_guy]

get you a whole new wire harness IMO.  You can eliminate alot of the switches if you don't want them (sidestand, nuetral, clutch) a new ignition is 32 from suzuki, vortex sells gas caps, and the seat lock can be easily removed and changed to not require a key if you so desired.  I know for a fact there is a motor for sale in orlando, FL for 100 but it needs a rebuild,  also there is one for sale in austin for 300 good motor.  they are both available here..  Good luck..  I'll be done with my bike as soon as I get home.

[rubberpenguin16]

Yea i am currently working on the pics for you guys (before... well during really) but yea im trying to get an engine but i cant do local pickup and noone wants to crate one and ship it... this is a big problem as i dont want to spend the 200-300 extra just to pick it up when i havent even titled the bike yet and dont know if the state will grant me a bonded title or not. so yea... ill keep this updated and the tips are always appreciated

[rubberpenguin16]

ok I think i got the pics figured out.



Thats the bike from the right side a month ago. sittin on my motorcycle lift.



This is the NASTY "Aftermarket" headlight and you will see the bracket in a minute. i HATED the fering so its going in the TRASH PYLE!





Look at the gap there because of the headlight and fering bracket... it looks HORRIBLE!



Can someone please explain to me why i cant find these handlebars ANYWHERE in a parts catalog... PLEASE?!? it could just be that this is my first experience with the GS and i havent looked into what years they changed what...



This is the current state of the engine... look at the corrosion! AND I HAVENT EVEN GOTTEN STARTED!



This is just the parts corner... not much but i gotta keep it clean

[annguyen1981]

According to the main site for this board, the only year clipons came with these bikes was 1989.

I'm assuming those are just aftermarket

[rubberpenguin16]

That was my guess too... im not sure i like them... any suggestions on how to change them back? i am fairly positive this in not an 89... i checked the vin or whatnot and the MFD

[pantablo]

definitely aftermarket clip ons. they also pushed the fork tubes up through the triple to get them to mount, by the height of the mount. You're missing the entire handlebar mounting bracket. Get those peices and you can go back to stock (or aftermarket lower) handlebars. The fork tubes where they are will seriously affect handling-twitchy on the interstate, great handling in the canyons. 89 clip ons were totally different, using a different top triple.

[makenzie71]

That gap doesn't look too bad...if it had a fairing up there the bracket wouldn't have been noticeable at all.

BTW, those look like old-school harris clip-ons.

[JamesG]

Ebay is your friend!

Yeah that motor is toast. You could probably salvage the cases and gears and crank, but thats alot of work. Easier to just find a good motor from someone and pop it in and offset the cost by cleaning up (at least get the rat nest out of it!) and selling the old one.

Yeah those are very old school clipons. And I'm kinda digging the rat bike square head light thing. Adding an oil cooler right under the light and leaving a mass of wires and plumbing exposed would make it perfect (mess).
:mrgreen:
If not, you will need the top triple clamp cover, which is what the instruments and bars bolt to on a stock GS.  Lock sets can be had and don't require any mangling of wiring.

I'm kind of envious. When I get home I want to find myself a similar project to nurse back to health.

Good luck!

[Simba]

That looks like a sweet project bike

Can we get pictures of the old faring? Just want to know what i looks like.

[rubberpenguin16]

I will be working on it tomorrow and i will get some more pictures for you... some closer of the weather damage to the frame and stuff too... even if i wanted the fairing i dont think its reusable... it supported the bike's weight the whole time it was on its side in the barn so its bent pretty well out of shape when its attached... it looks fine when its removed though so its possible its the clips too.

[rubberpenguin16]

i just dont like the fering at all... the second shot im just holding it up with my hand not even where it should be... and it does look pretty good and better when its actually clipped... idk what do you guys think?[/url]

sorry for the large pictures... wasnt using my own software or camera...

[pantablo]

its unusual. I kinda like it in a retro 70's sort of way. If its color coordinated it should look pretty good. its to your taste though. I'd keep it.

[rubberpenguin16]

If i can straighten it... i might for a while... i cant afford to replace all that i want right now anyway... riding condition is my main concern for now... im going to attempt to straighten it though and if it grows on me... it will probably stay... i like the fact that i havent seen a single other GS like it.

[JamesG]

WhooooaaahhhhH!!! BIG PICTURES!!!

can you scale them down a bit?

I think once you get it cleaned up and repainted it will look pretty cool in a retro sort of a way. You can actually have a lot of fun using an early 80's theme to the customization cues on your restoration.

[rubberpenguin16]

im working on the pictures... putfile is not cooperating with me very well. i used another one of my own homepages to support those two and thats why they are just full scale shots.

[rubberpenguin16]

There! Pictures corrected 

well... i have been BUSY 
Just since the Forum went down this is the change in my progress since the first pictures. 







Both wheels removed
Front brake system fully disassembled
Rear sprocket and rotor removed from wheel
Wiring harness finally FULLY removed
Rear caliper disassembled
Front forks disassembled
Handle bars disassembled and replacements located (very exciting)

i dont know what else i did i have covered so much on it since i got my tools back from work (changed jobs... tools not needed at the new one)

if there are any how-to's people would like to see from me let me know... i dont know what has been covered on here and what has not... on reassembly i intend to make one for mounting Clip on Handle bars for sure.