Got myself in a gs 500 project by accident

[weerstandje]

Good day everyone, I wanted to show the project I'm currently working on.

It all started when I needed new tires for my gs500, cheapskate as I am I first looked at the second-hand market and there she was.
a totalled gs 500 with almost brand new pilot street radials !! and after some bidding, it would only cost me 40,- bucks more than new tires.

The deal was made and I picked it up.


Back at home I was amazed about the overall state of the bike, yes the headlight, left clip-on and the right engine side where gone (must have been a strange accident) but the rest of the parts wherein mint condition!

Swapped the tyres to my main bike and removed all the broken parts and was even more amazed when I noticed the frame and front fork where perfectly fine as well. at this moment you could see the dollar signs in my eyes even more as i hade planned to sell all the good parts.


During dinner, i start to overthink the situation and i came to the conclusion that i just couldn't bare to take this beauty apart, i have to make it running again.
So that is where we are now, I'm trying to fix the gs with zero experience in motorcycle repair!

Meanwhile, my main gs is looking sexy as hell on her new tires and white rims 
Used to be: (Next to my nice weather bike)


Current:

[weerstandje]

The first task is to make the engine running again, the right side of the bike must have been dragged over the asphalt for some serious time cause the pulse giver is nowhere to be found and also the bolt that holds the stator is broken off.


i tried to drill out the bolt and fix the threads, unfortunately, the hole i drilled is not perfectly straight as I can see when I spin the crankshaft, I hope this wouldn't be too much of an issue with the stator later.

the next task is to get something for that little pin, I think I just make it an m3 hole and put a little bolt in it with the head sawed off.

i will keep you updated!

[qcbaker]

Don't have much advice to give, but I'll definitely be following along with your journey. Good luck!

[weerstandje]

Here is a small update from my garage,
i installed a new pulsgiver and the engine started almost immediately ! everything sounded fine so i spend the last days finding and ordering all the parts i have to replace. i am especially very curious about the headlight i ordered from china



i am still figuring out how to get the little pin out of the crankshaft axle, the pin is broken of and drilling it out doesn't work cause the material is so hard.

in the meantime i slapped some epoxy on the gas tank and spend the whole weekend sanding,
it looks quite nice now, no sign of the huge dent that the clipon made during the crash.
too bad the original paint is so expensive but i am going to order it anyway.


so that's it for now, if anyone knows how to get the pulsgiver stator pin out please let me know 
keep you updated !!

[cbrfxr67]

sub'd!

[weerstandje]

little update here,
the gs is running again !!! i wasnt able to get out the little pin so i just put the rotor back and got lucky,
meanwhile my other gastank is painted and ready to be mounted,
so the only things i need now is for my headlight to arrive and a solution to fix the little pulsgiver pin.
im thinking about just gluing a piece of 3mm plastic in there (drilling the broken bit out didn't work cause the leftover part is spinning allong.

cheers !




https://i.imgur.com/ldAWhVL.gifv

[weerstandje]

Cant wait for the decals and headlight to arrive !

[The Buddha]

Euro high rise clip on's, yeaaayyyyy worth a 100 in themselves.
Watching with great interest.
Cool.
Buddha.

[weerstandje]

Euro high rise clip on's, yeaaayyyyy worth a 100 in themselves.
Watching with great interest.
Cool.
Buddha.

Got some leftover parts if your interested 

[weerstandje]

headlight was plug and play !!
really like the look of the black case.

Next step is to touch up the frame paint, decals and repaint the exhaust pipes, somebody got anny advise how not to brake the bolts when removing them ?

[tobyd]

quite envious of the white wheels, i think mine is the same colour but has sort of gunmetal ones that are a bit 'meh'

re: exhaust bolts. I made a real mess doing mine and snapped three. If i had to do it again I'd cut the exhaust off around the bolts first to relieve any tension. Definitely replace the bolts with (min 50mm) studs if you plan to keep it.

I have a euro facing headlamp if you are interested in a spare (my bike was originally French)? the glass is in good shape, the rest only so-so but is angled for continental roads, so not great for me. yours for postage (from the UK, can't be much to NL though), let me know if interested and i'll find out the rates!