My rebuild :)

[dransy]

Hi guys been on the forum for a while but dont think ive ever really posted!
Here is my rebuild im currently doing , im copying and pasting it all from another forum i have it on at the mo , so if it doesnt make sense i dont mind answering the questions



Basically i was going to rat it out but then when i got into the build i started getting a little bit adventurous

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

So here we are 4 years later!!!



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 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!



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



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



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!



So wheel back on table on floor and that big thing is the spare back for our leather recliner   :lol: 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.



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. 

[dransy]

 I have ELECTRICITY in my garage  :lol:  :lol: 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!





urgh ugly

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

and vala





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



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



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.



The airbox only went on one way *obviously* but then my tank woudnt sit properly so i lit a nancy boy 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!!!


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



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 .

[dransy]

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.





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!!

[dransy]

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

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

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

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



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

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!!

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 !!

http://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 :D

[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









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

Before



After

[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





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!







I dont know what it will be like with the mot? but its cool

[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 poop!! And we all know you cant polish a poop!

Well its MY poop 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 c@%t! So i got my checker plate out again :D

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


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



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









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

[dransy]

This is where im at right now , ive also got a new rear tail light , indicators , chain and sprockets , exhaust gaskets , oil filter , pistons and seals for the front and rear calipersand i think thats about it for now ill keep on updating as im going along but theres not much left to do now

Got a bit of work to do with some plate and my welder for my new tail light and ill also be drilling into the rear sub frame to run the indicators wires up .

Ive completely reworked the entire wiring loom aswell as it was in a right state ! no pics of that at the moment but it was a nice job to do in the house

[Phil B]

Threads are always more fun with pics. thanks for posting em

Would be nicer if you scaled the pics thouh

Theres a trick if you dont have control of the remote side: hand code a "width" or "height" in the img tag. browser magic will automatically scale the other dimenstion to match.

Thusly:

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


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



.... (and so on)

Could be nice if you went back and edited your earlier posts, too...

I used exactly 1/4 of your original width sizes:  (img width=388)

[dransy]

Thanks for the reply phill, in all honesty I thought it was because I was on the missuses laptop and her screen is smaller ! 

I'll try scale them down when im home from work .

[dransy]

scaled pics down:D

[cbrfxr67]

Then what happened???  Shazamming!