Krav's 1999 GS500E Project (Big checkup + dyno run)

[crispy_22]

Welcome to the world of the UJM aka Universal Japanese Motorcycle. Many parts will interchange without modification. Many more with some modification

I'm finding that out more and more every day.

I was just curious as to the size of the 1st gen SV650 mirrors, like the diameter, I cant seem to find the answer anywhere and no one seems to have these mirrors.

[Krav]

I have no idea where my mirrors came from. But since there's a cheap carbon print on the back of em, i expect that they're indeed japanese :p

Update 2 September 2014

A small update. i bought 2nd hand suzuki mirrors, and a new headlamp + mounts. This because my old headlamp and mounts got crushed in my little crash. The more cunning of you may see that my tankguard is gone. Well :p an 8 euro tankguard apperently has the stickingpower of soap or something, because it came of not 10 hours after putting it on :p Im going to give it a try with hot glue.







A small little update, but next one is going to be auite a lot bigger. Then ill be tackling a new dashboard, and new LED blinkers + LED traillight.

But thats it for now!

Ill keep you guys posted!

[Swift63]

Great bike I love the ideas so far, I am working on a '95 GS500 right now and the previous owner had laid it over also. The gauges while cracked still work but I want new ones just to upgrade the look a bit. Did you end up just getting stock replacements or springing for some digital/chrome upgrades?

[Krav]

Update 30 September 2014

TEASER Time!

[dB-tje]

Nice a new type rear end!
Nice oud papier box do

[Krav]

Update 2 October 2014

So i installed my new rims with Michelin Pilot streets! i must say: They look sweet!
after solving a little problem with the outlining, the ride stability has improved much, i must say!
These tires feel way more grippy, something i used to have problems with before.



Also got a package today!
Ill upload some pictures of the mounting and tuning process.

[Krav]

Update 26 October 2014

Got busy with my Tank and seat today. Pictures tell more then 1000 words, so here it is.



In progress:



In progress still:



Finished product for today



Ill take the back plastics to work tomorrow, where i can work on em in the workshop, to make em fit. Or maybe, ill cut off the arse completely, i dont know yet.

Anyways, thats it for now. Let me know what you guys think:

1. Cut arse off!
2. Make the back plastics fit!

[Krav]

Update 28 October 2014

Today i finished up the taillight mount, and mounted the new plastics to my old frame. This being the result:

How i made the plastics mounts:



How it looks now







Also, tomorrow i've got another thing coming



Ill be bach!

[GS500Schultz]

you sir have inspired me to just buy all the newer gen stuff.

hows the seat mount up? i saw there was a bit of a gap between the seat and the frame. Any issues with passengers?

[Krav]

So here's the thing. The gastank will mount, no problem. The seat in turn, will mount on the gastank and the lock aswell. the rubbers under the back of the seat will float, as the contact point for those lies about 5cm higher. even though i havent fixed that up yet, its an easy fix.

I just need to fabricate 2 blocks of 5x5x2 cm. preferably steel or something. then what you do is drill  a big hole halfway trough the steel (on a 5x2cm side) and then drill a smaller hole in the middle of the big hole and out trough the bottom. that way you can screw it all into place on the flap below it all.

It may be a bit of a weird story right now, but when i've done it ill post the result. its fairly easy really.

Ill see if i cant explain it with a nice paint picture

EDIT> Paint picture failed :p ill post a picture when mine are done.

[GS500Schultz]

I'm pretty sure I understand what you're getting at.

Over this winter here I'll be collecting parts. Anything in particular I should look out for?

[Krav]

All the parts i used came from a 2003 bike with its engine blow.
That way i could be sure the parts fitted together nicely, since it all came from a single bike.

for the rest, it was mostly a bit of creativity and spare steel parts wich i could hammer, drill, grind and tap into the shape i needed em to be. a welder could come in handy aswell.

[Krav]

Update 2 November 2014

Yesterday, i fitted a refurbished 1999 suzuki gsx 600 katana shock to my lovely gs500. Height difference is pretty much absent. I wanted to have it tuned aswell, but i ran out of time.
Im still looking for a how to to adjust the rebound dampening, but the preload i know how to do.

This was my table yesterday morning:


And this is the shock installed:




Right now this is the parts i still have to fit. Excuse the exhaust manifold, for its at a sandblaster's. itll be back by monday, and then i can paint it


The fork oil is for next month, when i get my new progressive springs (tips where to get it in europe anyone?)

[Krav]

Got my exhaust back from the sandblaster's. This is the result. Not as good as i hoped, but then again, it was only 40 euro's. the grey paint im going to spay it over with, will make it look very nice, im sure.

Can't wait to have it sprayed, and mounted on my bike







I noticed the little hole in the collector. I blew into the exhaust, covering the exits, and it is airtight!

[GS500Schultz]

Make sure you bake yourexhaust 1st to get the moisture out beffore paint. If you Dont it will cause bubbles in your paint when it gets hot and ruin your paint job.

I run a small powdercoating shop and it looks like the sandblaster didn't blast the whole thing as I still see large patches of rust.  Sand that down first trust me!

[Krav]

I appreciate the tips! especially since you know your stuff (running a powdercoating shop) but i have no access to such an oven (size), but the instructions from the paint manufacturer doesnt say that i should heat it, and people who used this specific paint online, havent preheated either. it does say however, that the to be painted object should be in a roomtemperature for 2 hours, so that's where it's been sitting for now.

i think i might indeed sand it before in some area's.

thanks for your advise!

[GS500Schultz]

The oven is the best way but, a heat gun or torch also works just fine. 

You have to get the metal hot! to where it starts to smoke/steam, then let it cool and hit it with some of the high temp/flame proof paint.

[cs coupe]

Newer tank/fairings are a big improvement man. Well done. Let me know how much better the k&n lunchbox is over the pods. Might upgrade if its worth it.

[Krav]

My expectations are:
- No power difference
- Less sound
- easier to tune (carbs)
- less prone to outside temperature and own temperature differences.

the last 2 reasons were the main reasons i decided to go for this filter over my pods. im gonna miss the sound, but today ill mount my takkoni exhaust anyways so f*ck it!

[Krav]

Update 7 November 2014

Yesterday, i tried for an hour to get the old exhaust manifold off. those STUPID imbus bolts were not going to come off. one came off, the rest of the imbus bolts stipped away. even induced heat and WD 40, yet the screws wouldnt come out. so i've learned that ill have to live with this manifold untill i get my engineblock of the bike. good times

Anyway, after 10 minutes of grinding and sawing i done away with the old muffler, and installed the slip on Takkoni one.

it sounds great i have the DB killer, but not installed. this is what it looks like!






I also set my eyes on a go pro. found one for not too much money, with very tolerable quality. Cause, my bike now sounds great, is an awsome ride, but im kinda bugged that i now can only post photo's. The way photo's say more than 1000 words, a video can (literally) say more then 1000 photos

Maybe ill go motovloggin, who knows



Here's a samplevideo of the product, for only 150 euro's including  barmount.