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Resurrecting a '93? GS500e after 10 years - My first bike rebuild!

Started by Jem767, February 02, 2017, 11:05:55 AM

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J_Walker

The side the stator is on, on the underneath where the two case halves come together [not the oil pan] is there a bolt under there with an Oring?..
-Walker

The Buddha

Quote from: Jem767 on February 20, 2017, 06:21:20 AM
So I'm slowly making my way...

Got most of everything swapped to the new engine. Remind me for the future I don't like stators. Didn't realize it needed a special tool for the first ten minutes, then made two trips to AutoZone, then finally said "F it" and Jerry rigged something to work. :2guns: Gotta wait for a couple parts to finish though. The intake manifold seals crumbled into a million pieces, and I gotta dig through the parts bucket again cuz I can't find the starter cover anywhere. But, I got lucky, the clutch seems to be in fairly good condition. :thumb:

Picked up some new spark plugs while at the store  (the first time), plan on doing a full tune up before it's done. Might as well, right?

Pretty pictures!
Need to clean and shine it up!

New vs old.


Rotor comes off with a 14mm front axle bolt and a sliding hammer. I had one made about 10 yrs ago that would made mince meat of that rotor even when it was super super super tight ...
Now that the rotor is off, you could remove the valve cover and cam shafts and that way the motor slides into the frame a lot easier.
Its much much harder with those parts on, but doable.

Cool.
Buddha.,
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I run a business based on other people's junk.
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Jem767

Quote from: J_Walker on February 20, 2017, 01:55:02 PM
The side the stator is on, on the underneath where the two case halves come together [not the oil pan] is there a bolt under there with an Oring?..
I would have to check. It's been sitting on the bench the whole time we've been working on it.

Quote from: The Buddha on February 21, 2017, 07:41:25 AM
Rotor comes off with a 14mm front axle bolt and a sliding hammer. I had one made about 10 yrs ago that would made mince meat of that rotor even when it was super super super tight ...
Now that the rotor is off, you could remove the valve cover and cam shafts and that way the motor slides into the frame a lot easier.
Its much much harder with those parts on, but doable.

Cool.
Buddha.,
Yeah, we didn't have the slide hammer. Went to auto zone to rent one and what they gave us didn't work. Went back and the other thing they gave us didn't work either. Ended up going back and getting something else that finally worked.

The engine on the left is the "new" one, the one on the right is the busted one. We pulled it from the frame before disassembling everything else, whole. I have no idea what the plan is for putting everything back together, being a newbie to mechanic-ing I just follow orders!  :embarrassed:

Hopefully, the frame gets finished by Saturday, I'm waiting for them to call. If that happens, things will slowly get reinstalled on the frame bit by bit, fixing as we go. (It's not the only project running right now, we have a F250 in need of work and an  Altima with a blown engine.) The two major time factors are simply having time to work and waiting for parts to arrive.  :dunno_black:
Current: 09 Rebel 250 | In Progress: 93 GS500e

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