THE BASKET-CASE IS FINALLY HOME!!!

[Daeouse]

NICE Daeouse!!! I got my degree in fine art/graphics almost 6 years ago so photoshop, graphics etc. catch my interest all the time 

I hope to use my modest skill to create a full visualization of my final goal, if I can find high enough resolution images of the stuff I want. . . LOL!

[lucas]

The majority of the bolts on the GS are M6 (6mm in diameter) and have a thread pitch of 1.0 (that is threads per mm in length). 

The next most common size is M8 1.0.

There are a few M5 and I think an M4 somewhere.

You'll need various lengths.  I started by buying the lengths of bolts that I needed but I ended up making way too many trips to the hardware store.  I found a place online that sells stainless bolts and I bought between 10 and 50 of like every metric bolt I thought I'd need.  I got the highest quantities in the M6 range and got each size from 10mm long out to 30mm.  Also picked up boxes of washers and nuts from M3 to M8.  I got a plastic organizer bin thing and laid them out.  Now whenever I need a bolt I have my own supply.  I spent like $90 in all but I have saved more than that in gas and hardware store mark-ups.

I may have gone overboard with the bolt purchasing, you don't have to spend $90.  The bolts are only a few cents when you buy them in bulk though.

Something I'd do differently next time is shop around more.  The hardware I got isn't the best quality, though it is better than hardware store stuff.  I would buy a couple bolts at first and take a look at their quality and make sure that they aren't made out of cheesy soft metal.

[Daeouse]

The majority of the bolts on the GS are M6 (6mm in diameter) and have a thread pitch of 1.0 (that is threads per mm in length). 

The next most common size is M8 1.0.

There are a few M5 and I think an M4 somewhere.

You'll need various lengths.  I started by buying the lengths of bolts that I needed but I ended up making way too many trips to the hardware store.  I found a place online that sells stainless bolts and I bought between 10 and 50 of like every metric bolt I thought I'd need.  I got the highest quantities in the M6 range and got each size from 10mm long out to 30mm.  Also picked up boxes of washers and nuts from M3 to M8.  I got a plastic organizer bin thing and laid them out.  Now whenever I need a bolt I have my own supply.  I spent like $90 in all but I have saved more than that in gas and hardware store mark-ups.

I may have gone overboard with the bolt purchasing, you don't have to spend $90.  The bolts are only a few cents when you buy them in bulk though.

Something I'd do differently next time is shop around more.  The hardware I got isn't the best quality, though it is better than hardware store stuff.  I would buy a couple bolts at first and take a look at their quality and make sure that they aren't made out of cheesy soft metal.

I'll definitely look into that. I prefer Stainless hardware, so I think I'll be ok on quality. 

NICE Daeouse!!! I got my degree in fine art/graphics almost 6 years ago so photoshop, graphics etc. catch my interest all the time 

Then you'll like my overall concept: 

(Its a little rough around the edges, but I just wanted a quick(ish) idea of where I'm going. Took about an hour, but I think it was worth it!)

Thoughts?

[fresh]

The majority of the bolts on the GS are M6 (6mm in diameter) and have a thread pitch of 1.0 (that is threads per mm in length). 

The next most common size is M8 1.0.

There are a few M5 and I think an M4 somewhere.

You'll need various lengths.  I started by buying the lengths of bolts that I needed but I ended up making way too many trips to the hardware store.  I found a place online that sells stainless bolts and I bought between 10 and 50 of like every metric bolt I thought I'd need.  I got the highest quantities in the M6 range and got each size from 10mm long out to 30mm.  Also picked up boxes of washers and nuts from M3 to M8.  I got a plastic organizer bin thing and laid them out.  Now whenever I need a bolt I have my own supply.  I spent like $90 in all but I have saved more than that in gas and hardware store mark-ups.

I may have gone overboard with the bolt purchasing, you don't have to spend $90.  The bolts are only a few cents when you buy them in bulk though.

Something I'd do differently next time is shop around more.  The hardware I got isn't the best quality, though it is better than hardware store stuff.  I would buy a couple bolts at first and take a look at their quality and make sure that they aren't made out of cheesy soft metal.

I'll definitely look into that. I prefer Stainless hardware, so I think I'll be ok on quality. 

NICE Daeouse!!! I got my degree in fine art/graphics almost 6 years ago so photoshop, graphics etc. catch my interest all the time 

Then you'll like my overall concept: 

(Its a little rough around the edges, but I just wanted a quick(ish) idea of where I'm going. Took about an hour, but I think it was worth it!)

Thoughts?

This is awesome. Subbin' for more concepts.

[Daeouse]

This is awesome. Subbin' for more concepts.

Ask and ye shall receive!

Because I'm such a Gundam nut, I did a coloration based on Char Aznable's "Sazabi"  from Mobile Suit Gundam:

[lucas]

You might be surprised at what retailers will pass off as "stainless"

Always be skeptical.  Much of what you see online is made with little or no quality control.

[Daeouse]

You might be surprised at what retailers will pass off as "stainless"

Always be skeptical.  Much of what you see online is made with little or no quality control.

Very true, but I go to Ace Hardware, where I can be sure of its quality. I used the stainless bolts on my Motorized Bike build a few years ago and had no issues at all. But I'll bring a magnet just to be sure. 

[Joolstacho]

Re: the graphics... Less is more.

[Daeouse]

Re: the graphics... Less is more.

[lucas]

Not all types of stainless steel are magnetic 

Counterintuitive because iron, the main component in steel, is supposed to be magnetic.  But it's true 304 stainless among others are not magnetic.  I have some bolts that don't stick to my magnetic tray while I'm working and it gets annoying sometimes.

[Daeouse]

Not all types of stainless steel are magnetic 

Counterintuitive because iron, the main component in steel, is supposed to be magnetic.  But it's true 304 stainless among others are not magnetic.  I have some bolts that don't stick to my magnetic tray while I'm working and it gets annoying sometimes.

I worked in a manufacturing plant and frequently encountered all types of stainless, so I agree about the magnetism. I was taking the magnet to ensure the bolts weren't magnetic, as the stainless alloy I know I want isn't.
As for losing them, I feel your pain, I dropped the bolts a few times in the dirt when working on my motorized bike and swore up a storm sifting the sand to find it! LOL!
Would this place be good to use as a guide for bolts to get? http://www.suzukipartshouse.com/oemparts/l/suz/50d3f3d9f8700230d8b4c1fb/1995-gs500e-parts

[Daeouse]

Got some work done yesterday on the bike, but forgot to take pics. (oops)
I went down and bought some grade 8 M6 bolts from my local Advance Auto and secured the plastics, the foot guard on the chain-side,  and fiddled with everything.
I freed up the rear brake a bit more, but when the repair manual comes in I'll tear it down and clean it out to ensure safe operation.
I pulled the spark plugs again, oiled the upper cylinders a little, gently selected the highest gear, and rolled it forwards to ensure the engine cycled freely. All seemed well there, so I'm really happy there.
Once the manual gets in I'll start tearing the bike apart section by section and making any repairs I can  until I have the money to get the ignition switch.

[Daeouse]

More good news! This afternoon I just found out I got the job at the local Advanced Auto, so that means more money coming in to do repairs! 

[ShowBizWolf]

Very sorry for the delay in replying... I really really like your concept... it flows well and I love that blue color 

Stainless ftw 

Congrats on the job!!! That's super awesome... and I bet you'll be able to gather all kinds of knowledge (good AND bad haha) in a parts store, as well as some good WTF stories! 

[Daeouse]

Congrats on the job!!! That's super awesome... and I bet you'll be able to gather all kinds of knowledge (good AND bad haha) in a parts store, as well as some good WTF stories! 

Thanks! I worked in automotive parts before, and I can attest that the stories can get pretty crazy sometime! LOL!

[ShowBizWolf]

I've spent a lot (and I mean a lot) of time at my dad's (car) garage and also a close friend of my family works for napa... the stories ya hear and the people ya meet... very interesting !!!

[Daeouse]

I've spent a lot (and I mean a lot) of time at my dad's (car) garage and also a close friend of my family works for napa... the stories ya hear and the people ya meet... very interesting !!!

Oh yes. . . red-neck engineering and stories of stupidity abound!


=============================Regular Update=============================

My manual came in today!
Work can begin anew as soon as my friend can drop it off! 

[lucas]

If you're going to replace your ignition switch you can kludge together a "key" of sorts.  Unplug the ignition switch FIRST, cut the wires so that you have the green plug and a few inches of wires, strip them and either use splices, solder, or even twist the wires together.

The red and orange wires go together, the brown and... green go together.  Not 100% on those colors, but the wires are very different in thickness the red and orange wires are thick and the other two are thin wires.  If you want, consult the wiring diagram to see which colors get connected together by the ignition switch for reference.

Then you have a "key".  You just plug this thing onto the wire harness and the bike is on.

I did that at one point during my ignition switch replacement saga.



I have a supply of electrical terminals so I wired it up without doing any splices.  Just showing off I guess,   I probably should have just twisted the wires together.

[iamhiding]

thats actually a really good idea lucas

love the idea of removing the switch or relocating its original position but unfortunately needing the steering lock has always stopped me.

//

interesting concept daeouse, blue one looks quite good, simple/subtle is much better. two things though, the fairing is sitting too high on the bike, it looks good with the belly pan being quite snug to the exhaust but the headlight and screen are miles too high. really don't think the busa'esque headlight is suited to the bike, busas have to be one of the ugliest bikes on the go, nothing but bulbous undefined shape. what i reckon would be sweet is something to the a nc30 headlight or slabby/slingshot gsxr just an idea but it would be a nice classic/modern twist. but yeah the gs is very narrow, you wouldn't want the fairing to swallow the bike.

[Daeouse]

interesting concept daeouse, blue one looks quite good, simple/subtle is much better. two things though, the fairing is sitting too high on the bike, it looks good with the belly pan being quite snug to the exhaust but the headlight and screen are miles too high. really don't think the busa'esque headlight is suited to the bike, busas have to be one of the ugliest bikes on the go, nothing but bulbous undefined shape. what i reckon would be sweet is something to the a nc30 headlight or slabby/slingshot gsxr just an idea but it would be a nice classic/modern twist. but yeah the gs is very narrow, you wouldn't want the fairing to swallow the bike.

I couldn't find the right angle for the fairing, so I had to do a little editing to get it close. LOL!
I wanted to keep the "diamond" shaped headlight of the GSXR during the late 00's, but that's not a final thing, as that's way down the road. The AirTech fairing seems fairly good for the bike, but we'll see.

If you're going to replace your ignition switch you can kludge together a "key" of sorts.  Unplug the ignition switch FIRST, cut the wires so that you have the green plug and a few inches of wires, strip them and either use splices, solder, or even twist the wires together.

The red and orange wires go together, the brown and... green go together.  Not 100% on those colors, but the wires are very different in thickness the red and orange wires are thick and the other two are thin wires.  If you want, consult the wiring diagram to see which colors get connected together by the ignition switch for reference.

Then you have a "key".  You just plug this thing onto the wire harness and the bike is on.

I did that at one point during my ignition switch replacement saga.



I have a supply of electrical terminals so I wired it up without doing any splices.  Just showing off I guess,   I probably should have just twisted the wires together.

Unfortunately it's already been spliced, so a new switch will be installed. The only downside is trying to find a replacement for the seat key. I will then have three keys for my bike.  LOL!