2014 DUAL SPORT GS500 BUILD THREAD - LET'S DO IT!

[1200]

OK here I go. I have never done a build thread before but there is always a first time for everything, Right...  Like doing a dual sport make-over on a little two banger. Should be fun.

I came up with idea to even venture into the dual sport thing from a push from a friend who just bought and old beater KLR650.   And well, I couldn't say now to the offer from another friend to buy his 05 GS500F with 8k on it for $1300.  And the games begin!

So I jumped on here just to see what these bikes are all about. (I'm and old superbike nut with Hayabusas and ZX14's) A great site this is!  I ran into a few threads were this sort of mod had already been done. Thanks to all those guys who have gone before me and posted there mod info on this site and the various related sites. If it were not for your info and attention to details, I wouldn't even attempt this mod/conversion.

I will first start by loading up a few pics of the bike in it's stock form. Bear with me because I need to learn the formalities of GSTwin photo upload protocol. I will throw up a list of parts that I have slated to use on the mod (please jump in whenever you feel you have a better idea - I reserve the rights to make my own decisions though

Then I will chronicle the process from beginning to end , that is if  live thru it.... You can tell I love the wig-digs they make me laugh and we all need more of that in our lives...

See you soon

[1200]

HERE IS THE PROJECT BIKE:

2005 GS500F  Bone Stock!



THIS IS WHAT I HOPE TO BUILD!!!!!

[1200]

OK, so I have my homework cut out for me trying to figure out how to upload photos here. Good-GRIEF!!!  No way to edit a post either.... off to college I go

EDIT:  Ok, it's just me and my inabilities to navigate this site and not the good work of it's designers   See, I do kiss and make up

Just saw the quote button after @BockinBboy pointed it out to me in an unrelated conversation.  I also NOTICED! the "Modify" button of which I'm using right now to suck-up to the Moderators!!

Anyway, I got it! This part that is....

[BockinBboy]

Here you go! 

To see how I did it, just click the quote button on this reply.

To edit your previous posts, click the modify button next to the quote button of the message you want to edit.



- Bboy

[1200]

Dude, u da man!   lol...

I just got back on here to see if anyone thru me  a lifeline...  I took some more pics and wanted to load them up.  I have to go see what you did to load that thing.... you must have locked onto the URL that I pulled from photobucket.

Anyway thanks!

OK, so now you've seen ONE MORE GS!    Let's try to make thie thread at least interesting for the new modsters... we'll see.

[Big Rich]

Sign me up. I enjoy a good dual sport conversion as much as the next guy.

[gsJack]

[BockinBboy]

You mean you couldn't see that little pic Jack?!   

- Bboy

[gsJack]

Not without my glasses.   

[1200]

Even Bettter!!! gsJack Thanks to you and Bockinboy. Now I need to figure it out myself.....unless you guys want to bow up all my posted pics???

Here is the beginning list of things to expect:

2005 GS500F / KATANA CONVERSION TO DUAL SPORT

BUILD SPECS. PLANS

SUSPENSION    EDIT: 3/14/14  Before you run off and buy a bunch of parts, wait until I here from whoever owns the Model Bike that I hope to build. Apparently he has an easier way to do the Front Fork mod, not using the dual disc Katana Forks. For those who just want longer forks without the headache of doing new triple tree and the whole shebang! Just follow along, he will show up from somewhere and let us know what he did...

(Front)
Katana 600 or 750 up to 1987 will work (check on later models IDK)
Katana (96) GSX600F frontend - forks - dual disc brakes also adjustable
Katana ( 96) 600 upper triple and lower Triple
Katana (00) GSX750F Axle (it's longer than the GS)
SealSaver fork seal protectors
Stock fork oil
GS steering stem swap-will done to adapt the Katana 600 front end to the GS
Will need Custom Spacers to take up length on the GS to 600 Steering Stem (hoping for help form a GSTwin member on this
Adjustable Handle bar Clip-ons (because I want handle bars that are not low sport type) Katana clip-on will work
Stock handle bar controls carried over
(Rear)
Suzuki SV650 (yellow spring early model) rear shock-stiffer, more rearend height
Stock GS swing arm and linkages

BRAKES
(Front)
Katana(96) 600 stock dual disc
Katana (93) 600 stock 4 piston calipers x2
5 extra brake rotor bolts - must remove the plastic cover from stock rim if you decide to use it
Katana (93) 600 stock master cylinder & lever
GS brake Lever should work
Carbon Kevlar Pads

(Back)
All stock GS 500F (so far I plan to keep it this way)

WHEELS AND TIRES
(Front)
Stock GS 3.0 inch wheel-is the same as the stock Katana 600/750 up to 1987 front wheel so it matches the front end upgrade

(Rear)
Complete stock rear wheel @ 3.5 inch wide good enough

Stock 39 tooth GS sprocket

Tires
Both Shinko  Dual Sport 705's  These are a good between sport tire. Not too knobby for mostly street use.
(Size)
120-90-17 Front-up from 110-70-17
140-80-17 Rear-up from 130-70-17
FRONT FENDER
I'm working on which one will fit my off-road look.  If you want you can use a stock Katana fender.
*Credit for most of this plan design goes to:
@Dgyver
@ben2go
@some guy who has a lot of custom stuff done with many picks on Flicker
PARTS REUSABLE FROM YOUR GS500
- Front axle spacer
- Nut for front axle
- Speedometer pick-up
- Front wheel
- Right side spacer
- Rotor bolts (5)
BODY / FRAME MODIFICATIONS
Engine Guards – SW-Motech crash bars
Custom made Belly Pan......... this will be work
Custom made small saddle-bag holders
Dual Projector beam headlight aftermarket from china
Mini LED spot lights
LED turn signal from and rear that are close to the frame so they won't get snagged
Kickstand – extend the stock one
Hand brush Guards   some dirt bike ones I had laying around – see the experiments...

More to come........

[1200]

"PROJECT 2014 DUALSPORT GS500", PROGRESS SO FAR: 3/14/2014


Fairings are off but I kept the headlight on until I receive my new one in the mail:





Found a burned wire. Wondered why the Tach wasn't working?? I spliced and soldered-in new sections of wire and all is working again: Bit of an oil leak to at the valve cover...


This hose just fell out. Not sure where it goes on the engine, some sort of drain:


Can't seem to loose these brackets. They hold the oil cooler lines to the frame; maybe Ill mount some lights at the screw-hole bungs...



Donor mirrors from my old 1979 KZ1000. Almost threw them away, several times! Pack-ratting pays off!


New (used) SV650 Rear Shock:


Tire Comparison, Stock vs Shinko 705's. BTW, be careful with old tires. I see a lot of cracking in mine though the rubber has much treads left:







More to come, no doubt...

[BockinBboy]

On that tube that fell out... You've got three possibilities altogether - however, I'll give the best bet.

The larger of the two shown there should be your airbox drain - NOTE that tube should also have a cap type thing on the end - that cap thing lets gas out if carbs overflow into airbox, but should let not anything back in... so you need to get one on there. 

The smaller diameter tube right there should be your tank overflow (looks like the one in question).  That connects to the nipple on the underside of the tank next to the tank petcock.  You definitely want that on there so gas doesn't overflow over the top of a hot engine...

The other possibility is your battery vent tube... which connects to your battery and directs acid away from your bike if the battery were to 'spill' or overflow for some reason... but I bet the tube in question is actually the tank overflow.

- Bboy

[1200]

On that tube that fell out... You've got three possibilities altogether - however, I'll give the best bet.

The larger of the two shown there should be your airbox drain - NOTE that tube should also have a cap type thing on the end - that cap thing lets gas out if carbs overflow into airbox, but should let not anything back in... so you need to get one on there. 

The smaller diameter tube right there should be your tank overflow (looks like the one in question).  That connects to the nipple on the underside of the tank next to the tank petcock.  You definitely want that on there so gas doesn't overflow over the top of a hot engine...

The other possibility is your battery vent tube... which connects to your battery and directs acid away from your bike if the battery were to 'spill' or overflow for some reason... but I bet the tube in question is actually the tank overflow.

- Bboy

Bboy, I want to thank you specifically for taking the time to give attention to my project and all my questions.  I really appreciate people who have knowledge and are WILLING to share it, as opposed to those who has knowledge and don't care to bother taking the time to help another by SHARING it.

On the tube:  I will have to pull the tank to see what's going on with it, sooner rather than later now that you have lit the fire of urgency under my but about gas possibly going onto the engine - if its the fuel overflow tube. I'll post back with which it was.

Right now, I'm in a bit of a pickle with getting some Steering Stem Spacer turned down on a lathe.  I had anticipated @dgyver doing them for me, as he offered to do some for a few to those who needed them. Now he says his lathe is broken so I need to find someone with a lathe that is willing to turn the spacer for me - I would pay of course.

ANYBODY KNOW OF SOMEONE WITH A LATHE THAT HAS THE SMARTS TO TURN OUT THESE SPACES?  HELP!!!

These are the spacer that I need



This is where the spacer go on the Katana Triple Tree Stem.


This is everything installed: Katana front end with the spacers all pressed onto a GS500 Steering Stem.

[BockinBboy]

No problem 1200

- Bboy

[W201028]

1200, since you havnt posted in about a week, I am going to assume you ran into the same problem I did last week.

The yellow SV650 shock is not, and will never be, a direct bolt on. Even if you drill the lower mounting hole higher, the shock will either hang up on the linkage, or rub the swingarm, or both. These are serious problems.

Some members have welded extensions into the stock dogbones to raise the swingarm back up; I chose to make my own bones. If you are so inclined, I can give you some dimensions.

I am working on a similar project, Im hoping to finish tomorrow. I will upload some pics later.

Also, on redrilling the SV shock, theres a stamping on one side, I think mine was 189, not sure if its a part number or manufacture mark or what, but I drilled right on that 8.

[W201028]

Here is one of the dog bones after paint. I gave myself 2 options for height, one high and one low.


This is how it looks mounted, with the drilled shock joint visible.


Note the bare minimum clearance between the shock and swingarm. With stock bones, the arm rode the coil.


Here is the final product. See the 2x4 under the center stand? I can barely turn the rear wheel without dragging the ground.

[1200]

Here is one of the dog bones after paint. I gave myself 2 options for height, one high and one low.


This is how it looks mounted, with the drilled shock joint visible.


Note the bare minimum clearance between the shock and swingarm. With stock bones, the arm rode the coil.


Here is the final product. See the 2x4 under the center stand? I can barely turn the rear wheel without dragging the ground.

You just don't know!     I haven't gotten back to the project, just crazy busy with work!!!

Your post is right on time!!! I am getting a bit of a break and heading back to the project; ready to tackle the SV shock. Thank goodness you posted your experience before I got to it.... I am still waiting on a few parts to come in and prepping for doing the custom bushing fabrication listed in the pics further up this thread.

I got the idea to use the SV shock from a couple of the guys that have done mods on the GS, one is a member here, another on AVrider. 

Thanks so much for the specs on the dog bones!!!  I can make them or possibly find some on the same dimension online.

Just looking back at you pics:  I wish I had more space inside a garage to work on the bike. I'm out in front of the drive and at night forgetaboutit! I have an 86 mustang gt project going in the garage right now.

Let's stay connected. I want to hear more about your build. What frontend are you using?

[BockinBboy]

Although I have not done this particular mod before with an SV650 shock, I was not aware of any issues with the swap.  I could see there being a problem if you had shorter than stock dog bones (which would change the angle of the shock, and draw it nearer the swingarm), but not with the stock sized dog bones.  All references I see with the SV650 shock swap note that if you don't drill holes (and cut off the excess), you will raise the seat height about two inches - but, otherwise I've never seen anything noted about it hitting the swing arm.  The only known 'direct' shock swap that has such minimal clearance is the R6 shock, and even then it doesn't have to be modified.   



- Bboy

[illenium]

SV650 shock > I just ran into that this weekend. I drilled a hole into the bottom and it just
would not clear what i call the knuckle (not sure what the correct name for it is).

I tried for some time, measured the dog bones, they are stock, than looked into my
parts pile and gutted an 1989 swingarm with the cast aluminum knuckle, it's shape allows
to bolt it on and gives enough clearance (the 1/4 to 3/8 you need)

Be prepared to brace the bike up on a 2x4 as the center stand wont lift if high enough
to have one wheel off the ground after / when you put the shock in

Using that cast knuckle all you have to do is drill a hole in the shock mounting taps, about midway from the original hole to the top of the bracket and it will fit in as is (you dont have to
shorten the tabs).

So no modification to your frame other than the knuckle.

here is what i mean:

left side: newer still 'knuckle' off a 93
right side: old style 'knuckle' off a 89

[BockinBboy]

I was trying to say that its only a direct bolt on if you want the aprox. two extra inches of height without changing dogbones.  If you want same as stock height - you have to drill new holes AND cut off the excess where the old holes are, because that will interfere with the knuckle as illenium pointed out... I thought that part was well known... if you had different info, it mislead you.  SV650 shock is used most often used in builds that need/want extra height.  But regardless of this, it should not hit the swingarm unless there is something else different in there such as shorter dogbones.

Edit:
Here is wiki link.  Shows you need to drill new holes and cut off excess.
http://wiki.gstwins.com/index.php?n=Upgrades.RearShock#sv650

- Bboy