Bombsquad's 1993 GS500e refresh

[bombsquad83]

Tried to borrow a compression tester from autozone, but they don't lend a kit with the right size threads.  So, I ended up having to buy a kit.  Haven't had time to use it yet since the wife has me busy with house projects getting ready for junior.  I will get to it tomorrow.

[cbrfxr67]

then what happened??  need update!

[bombsquad83]

then what happened??  need update!

Hey!  Someone's watching... Will do the compression test after work today.  If that comes back ok, then I will be doing electrical system tests.  Any other suggestions are welcome!

[knowles]

I look at yours whenever there is a new post. I pulling for ya man.

[cbrfxr67]

You'll get it Bomb!  I really don't think it is compression.  I can only say what I'd do.  I'd prob check carb diaphrams (vacuum good?), or coils first(had this happen on pesky F2 not firing on all cylinders and coil swap fixed that issue).  Just going over the basics will get you on track sir.
Such a pita though when you put so much time in and then find one header isn't even hot.  Ugh. 

[steezin_and_wheezin]

i love seeing everyone's project build threads. you definitely have more than 1 watcher

[bombsquad83]

You'll get it Bomb!  I really don't think it is compression.  I can only say what I'd do.  I'd prob check carb diaphrams (vacuum good?), or coils first(had this happen on pesky F2 not firing on all cylinders and coil swap fixed that issue).  Just going over the basics will get you on track sir.
Such a pita though when you put so much time in and then find one header isn't even hot.  Ugh.

Really appreciate the encouragement guys.  I really like hashing things out with people throwing things out there.  Especially in this case when this is my first bike and I'm learning how to do this stuff. 

The carb diaphragms look ok, but it's not a bad idea to swap them and see what happens.  I already switched the coils and the plugs independently to no effect.  Thanks guys, and keep them coming!

[bombsquad83]

Now I'm thoroughly confused.

Started by rechecking my checking the torque on the camshaft bolts after calibrating my torque wrench (I won't get into this process now).  I also rechecked the timing.  Everything looked good and I put the valve cover back on and torqued it down. 

Now on to the compression test.  First I decided to do one cold test.

Left cylinder = 140 psi
Right cylinder = 140 psi

Now I'm thinking.  Great!  I probably won't have to rebuild.   So, I switched the carb diaphragms from one to the other and fired it up.  After realizing I need some longer fuel lines with my new petcock because the lines tend to pinch, it fired right up.  After just 10 seconds or so it shot up to 4000 rpm with the choke on.  I'm excited at this point because I know that's what it's supposed to do.  I take the choke off and it settles into idle at 1200.  Then the wierdness started again.  With throttle input it would backfire through the carbs a bit inconsistently, and then catch and rev great.  At this point I'm thinking this is all consistent with leaky diaphragms.   I shut it down.

Then I decide I might as well do a warm compression test.  Now this is where the real confusion sets in.

Left Cylinder = 110 psi
Right Cylinder = 120 psi

WTH!!  Shouldn't the compression go up once it's warm?

What's going on guys?  I haven't tried a little oil in the cylinder yet, so I guess that's the next step?  Maybe it wasn't all the way up to operating temp yet?

[bombsquad83]

All I can think about today is those warm compression numbers, and now I'm doubting myself as to whether I remembered to hold the throttle open.  Will test again tonight.

I ordered a couple new diaphragms on ebay as well.

[bombsquad83]

Got an update for everyone, and here is the good news.  I got to ride it today!  New diaphragms made throttle response much more consistent and got rid of backfiring through the carbs.  Redid compression numbers while she was nice and warmed up with the throttle wide open and got 135 in both cylinders.  Not great numbers, but acceptable for me I believe.  No difference points to another source for my left cylinder issues.  I also installed new exhaust gaskets.  I adjusted my throttle cable when I noticed that it would pull the throttle slightly when I locked the bars to the right. 

Still got some issues to work out though. 

1. Left cylinder still does not want to run when it's on choke.  It does sometimes when the bike is warmed up, but not consistently.
2. After riding her for a while. I started to notice a knock or a tick.  Most noticeable on deceleration.  I think it's in the valve train, but I'm not 100%.

I have video for both of these issues.  Will post them shortly.

[cbrfxr67]

At least you got to ride it a bit!  Definitely watching your progess!

[bombsquad83]

In this video you might here some of the knock.  You also see how it acts when I pull the choke.  At first, it starts to rev higher as you would expect from a warm engine with choke on, but then goes back down.
http://s265.photobucket.com/albums/ii224/dtilford/GS500/?action=view&current=IMG_1180.mp4

In this video you can hear the knock/tick...I think it's coming from the right side of the valve train.
http://s265.photobucket.com/albums/ii224/dtilford/GS500/?action=view&current=IMG_1182.mp4

[bombsquad83]

Rode it again this evening and didn't notice the knock.  I think it might be just the infamous intermittent camshaft knock that happens with pre-2000 (don't remember when they addressed it with different cam parts).  I'm not going to worry about it unless someone sees the video and warns me otherwise or it gets worse.

So that just leaves this annoying LH cylinder choke issue and paint left and she is done.

[ninjeff]

what are your plans for paint?

[bombsquad83]

I bought automotive grade high build primer and auto grade clear.  A buddy of mine has a good paint gun and a paint room for his woodworking business.  He also has left over electric blue metallic paint.  A sample of it can be seen in my first post.  He said it will look a bit darker once it's clear coated.

I'll link to the products if it turns out well.

Heres a pic of the bike right now in my handlebar thread.  It's more naked then naked right now.

http://gstwins.com/gsboard/index.php?topic=59572.msg687866#msg687866

[bombsquad83]

Here's the links to what I bought for paint, minus the base color which my friend has.  Bought it all through Amazon from TCP Global Corp.

Clear - http://www.amazon.com/gp/product/B004SQUCCS/ref=oh_o03_s00_i02_details
Primer - http://www.amazon.com/gp/product/B004SQTK9E/ref=oh_o03_s00_i03_details
Hardener (2 of these) - http://www.amazon.com/gp/product/B004SQU1X8/ref=oh_o03_s00_i01_details

EDIT: Asked my friend what he thought the base was.  He said it's Starfire brand urethane base, and it's Blue Metallic.  Here's the sample:

[bombsquad83]

Ordered a new set of Pirelli Sport Demons today.  I also have 2 sets of parts carbs coming from steezin this week, so I'll be trying to figure out why my left carb is running rich.  Still have to get the paint done, and figure out whether the ticking/knocking in the engine once it gets warm is worth looking into any further. 

Any input on the paint color, tick noise (video above), carb issue, or how to mount tires myself is appreciated!

[ninjeff]

I think the blue looks good. Classy.

If i may ask, how much did you pay for the tires? What size?

[hawaiianGS]

Great to hear it's coming together for you Bomb. Love seeing the progress.

[bombsquad83]

Item   Status   Price   Quantity   Total Item Price
Sport Demon Sport Touring Front Tire
Color- --, Size- 110/70H-17
SKU#54891   Approved   $102.99   1   $102.99
Sport Demon Sport Touring Rear Tire
Color- --, Size- 130/70H-17
SKU#54899   Approved   $115.99   1   $115.99
Assorted Tire Iron Set
Color- --, Size- 3-Pack
SKU#40970   Approved   $22.99   1   $22.99
Valve Core Remover
Color- --, Size- --
SKU#41081   Approved   $2.99   1   $2.99

Grand Total:
$244.96

That is my order from motorcycle superstore.