93 GS500E my turn for a build page

[EndlessProject93]

well, I've said once or twice the sad story of my 93. this is the last time  . I got the bike in a trade back in 2001. I rode it 2001 and 2002 then I transferred to Maine in the middle of winter. I left it at my parents house with the intention of picking it up the following summer. Feb of 03 I went on deployment and when I got back, it was August so winter was right around the corner again. I also came back with some extra money and picked up a Honda 450 cruiser for $500. I rode that around til the summer of 05 when I bought a Ducati Monster. I had that til the summer of 07 when I bought an 06 Suzuki M50 which I still have and I've put 18xxx miles on it. this past weekend, I finally picked up that 93 I abandoned in 2002. it is in rough shape, but salvageable. I'm planning on taking it apart, cleaning it up and probably chopping the tail as I've seen in a thread or 3 on here. at this very moment, I'm sitting at work but when I get home I'll post some pics. it's gonna take a while to get back on the road, but after 8 years, whats the rush?? I just hope it doesn't take me the 3 years its taken charlie lol.

Mike

[EndlessProject93]

ok I'm gonna give this a shot. I'm mostly computer retarted so bear with me. BTW I did look under the help section before trying this

I did actually start pulling stuff before I remembered that I should take pics. but when I brought it home it looked pretty much like this.



then I took more stuff off and it looked like this.

[saxman]

ok I'm gonna give this a shot. I'm mostly computer retarted so bear with me. BTW I did look under the help section before trying this

I did actually start pulling stuff before I remembered that I should take pics. but when I brought it home it looked pretty much like this.



then I took more stuff off and it looked like this.

You need to have the photos hosted somewhere other than facebook. www.photobucket.com works great.

[EndlessProject93]

sweet. thanks. I have a photobucket account.

[EndlessProject93]

OK 1 more time, before and after. I will take more pictures tomorrow.

[EndlessProject93]

so far, most everything has come off easy. surprisingly not much in the way of corroded hardware. the battery box has had it though.

[Fry]

Cool, I love any type of Build Thread, start twisting the wrenches, snapping pictures, and modd'ing the bike....

[JB848]

so far, most everything has come off easy. surprisingly not much in the way of corroded hardware. the battery box has had it though.

Crap, there is a secret mixture that I used on mine and it ate all of the corrosion..guys help me out I forgot what it was. I then used chemtool to clean all the residue off. Primered and painted it used strips of weather stripping inside to replace the factory stuff and viola looks just like new. Well mostly. After that I replace the vent tube and made sure the was space between the frame and the tube that there was no way the tube could come off or leak onto the frame.

[EndlessProject93]

Cool, I love any type of Build Thread, start twisting the wrenches, snapping pictures, and modd'ing the bike....

I turn wrenches for a living so that's the easy part. actual frame work may take some time. I'm not a welder and the guy who does all my welding is also in the navy and goes out to sea quite a bit.

[EndlessProject93]

spoke too soon. not that bad but I had to drill out the screws that hold what I'm guessing is the CPU (brainbox??) from the left side of the battery box. I meant to take some pictures today but I was busy all morning then had to work. I'll take some tomorrow. my garage has GS parts everywhere.

[EndlessProject93]

progress is slow right now. I'm still trying to decide exactly what direction to go with it. before I start cutting or chopping, I want to get it running again. I hooked it up to a battery today, I got lights but it wouldn't turn over. I got indicator lights on the speedo panel so the power is there. my kids were having a blast with the horn....little turds.... I know I have 1 busted spark plug wire but I ordered replacements from ebay. they should be here next week. as I was following wires, it looks like my sidestand wire harness is burnt up but the relay looked good. I found a wiring schematic so I'm gonna follow that and see what I can come up with. since I don't have much more to say, here's a couple of pics of my mess.





and 1 of my daily rider just for grins and giggles.

[Paulcet]

Woah!  She rides that every day!   

[EndlessProject93]

 gotta get her started early.

[JB848]

EndlessProject93 let me start out by saying TY for your service.
What was the outcome with the battery box? Also you never learned to weld in the Navy? Cool, NP have your buddy teach you. If you can wrench odds are you can weld.

Anyway get that old girl going! Post your progress when you can.

LOL, I thought my garage was a mess? But it looks like you have two little helpers there to make that happen

[EndlessProject93]

I'm not sure if I can save the battery box. no big deal, I should be able to make a new one.

I never learned to weld because naval aircraft are mostly aluminum and fastened together. very little welding is actually done. I've always wanted to learn, just never really had the chance. I plan on learning on this build.

now onto my question. I have a sealed batter attached to a trickle charger, I know the battery is bad, but attached to the charger I get lights. still no turning over. the kickstand relay was buzzing on saturday to the point you could feel it. yesterday, no more buzzing but I could hear it click when the key was turned on. I traced wires and couldn't find anything out of the ordinary. still waiting on the new coils and plug wires. could it just be the battery??

[seamax]

[/quote]

SQUID! 

[EndlessProject93]

looks like I need a multimeter. coils and plug wires came in today. installed and still nothing. I need to check the starter solenoid I guess. alot of this stuff was replaced a couple years ago by my dad because he wanted to use it as a commuter bike but lost interest. maybe I'll buy a new battery tomorrow. I don't think this one has the juice to do anything, even attached to the trickle charger.

[Paulcet]

Yes, a weak battery can cause a relay to buzz and click.

[the mole]

I'm guessing the buzzing and clicking was the starter relay, due to low battery voltage under load. Just jump start it from the M50. Leave the M50 motor switched off, and (if the GS has no battery) leave the jumper leads connected while you run the GS motor.

[EndlessProject93]

I'm guessing the buzzing and clicking was the starter relay, due to low battery voltage under load. Just jump start it from the M50. Leave the M50 motor switched off, and (if the GS has no battery) leave the jumper leads connected while you run the GS motor.

according to the diagram I saw it was the kickstand relay but I could be wrong (it's been known to happen) I'm going to buy a new battery tomorrow. hopefully I can get somewhere then. if not, I'm just gonna keep it disconnected as I go so it doesn't die too.