RGS500 Build

[rdhill]

I've always wanted an RGV250.  However finding one that can be licensed for street use is rather difficult and expensive.  So i've decided to build a replica on a GS500.  Here's my inspiration:  


To get started I contacted Roland Gimbel in Germany.  I received my fairings kit and rearsets from Gimbel a couple of weeks ago.  


So far my impressions of the fairings are good.  They received a couple of knocks to the corners of the fairings during shipping but nothing that I can't repair.  Since they were built about a week before shipping they are still curing and thus require some stretching and prying to get buttoned up to the stays.  My only complaint is their instructions are rather lacking.  Luckily I'm fairly fluent in German.   My overall plans are to get the fairings installed this summer and continue riding as I commute on my bike.  This winter, I'll strip the bike down and repaint the frame, components and fairings.  I have a Katana 600 front end for the bike that I'll install when I build the bike back up.

This weekend was fairly productive.  On Friday night, I managed to get all the fairing stays installed.  They went on rather easily.  Gimbel provides new longer bolds for the middle fairing stay that is installed on the front of the frame where the right side frame bolts in.  


I test fit the fairings on Saturday morning without a headlight or controls.  




Today I managed to trim the bottom right side for the exhaust headers.  By the looks of the opening on the bottom of the fairing it was designed around the stock exhaust, even though all the pics you see of Gimbel installation has a Vance & Hines exhaust can.  I also opened up the NACA ducts on both sides.  (Pic before trimming).  


After all the trimming I installed the fairings with the headlight.  It was extremely difficult to get the top fairing buttoned up with the headlight installed.
 


I'm leaving the fairings on a few days so that they can relax and fit properly.  I turned my attention to the controls.  I managed to get the left side of the bike's rearse installed.  I also installed both Woodcraft clipons.  before calling it a night.

[Falcon01]

Cool project!  What year GS are you using? 

[CptAwesome]

this is wicked. great idea

[rdhill]

It's an '89 and was fairly stock when i bought it.  The only thing that i've done to it so far was a Jardine exhaust system, K&N drop-ins, necessary rejetting, and superbars. 

[Tombstones81]

very nice!
but hurry up! haha j/k
watchin a nice build is like watchin a good movie.. just alot longer

wish I had the knowledge, tools, and money to do some of the minor and major custom changes to the GS500's I've seen on these boards! 

OT
this interest keeps up, I know what I'm going to school for now that my situation woes are otw out. 


(edit)
im not one for many sport bikes with fairings but that one I personally wouldnt hesitate to buy or build.

[the mole]

That's going to look great!

[Jim Knopf]

servus,

nice Project.

For your inspiration a pic for you:

[warlock214]

Man that's gonna be tight! Can't wait to see the finished product!

[cbrfxr67]

great stuff here!  can't wait to see how it ends up!

[fraze11]

Its stuff like this that makes this site great.  This is very cool!! Can't wait to see the finished bike as well.  I was always a fan of the RGT500 myself;

I posted this a while ago;
http://gstwins.com/gsboard/index.php?topic=53075.msg599262#msg599262

[nikfleisch]

Looking good so far! How much did those fairings run you?

[Shepa]

Nicccce project... 

Hope it will be in Kevin's Lucky Strike colours!!!   

[rdhill]

Not much to report tonight.  Started mocking up the right rearset.  I need to translate the instructions before proceeding.

@servus:  thanks for the inspiriation

@nikfleisch:  both arms and legs!  probably about $750 euro for the fairing set and rearsets. 

@Shepa:  i'm sticking with the Suzuki blue paint scheme.

[adidasguy]

Junior has the same seat and rear set. They work great.

Brake side: had to shorten the shaft on the master cylinder. A little tricky to put in the pressure switch but still did all of it in under an hour. Just bleed like crazy because a bubble might get stuck around the pressure switch. Managed installing it all in spite of the poor instructions. Been on Junior for over 6 months. Haven't had to touch it or adjust it since I put it on.
I guarantee you'll love the rear set.
I love the solo seat. I'm looking into holding the back cushion on with strong magnets. Then the area in the tail can still be used for storage. That's the only negative with that seat: it bolts on and takes away the access to the tool kit and where the registration is kept.
Can't wait to see your bike finished.

[rdhill]

I spend yesterday mocking up the rest of the fairing looking for fitting issues.  Here are a couple of pics from the front and back sides.  I still haven't fit the rear solo seat. 
 

There are still some exhaust header clearance issues. I'll trim some more with the fairing on the bike.  I still need to cutout the side openings. 


Another area that I'll have to work is the windshield seating area.  There differential thicknesses along the seating area not causing the windscreen and fairing to be slightly warped and rippled.  Nothing a Dremel with a sanding drum can't fix. 


The right rearset is almost complete.  Should have the master cylinder refitted today.

[xunedeinx]

This thread is awesome! That is going to look sick when you are done!

[cbrfxr67]

Are you going to use those mirrors? 

[rdhill]

I think so.  I kind of like the looks of them plus they work quite well, especially compared to the stock mirrors.