Classified Moto inspired build

[jarrodblake]

Hey all I just picked up my first bike. Its a 1989 GS500E and it needs lots of attention. I bought the bike looking for a project, that said I need another project like I need another hole in my head but I have been wanting a bike for years. However when I started my search for a bike I would have never dreamed it would be a GS500. I had always planned on buying a late 70s early 80s Honda CB and do KT600 inspired build. But I came across a the GS500 and other then the frame it checked all my boxes for a build candidate. it's mostly complete, it already have a bit more modern suspension. Its air cooled, chain driven 2 cylinder and it has a clear title! So the bike currently does not run. The wiring harness is all cut up and the bike was spray bombed. Its missing its gauges and lights. The tank is completely rusted out and seat and seat frame are cut up.

My plans for the bike are if I can get it running is to go through everything and refresh it. Do a few upgrades then do a classified moto inspired build. I love their frank build. So far I have ordered a new wiring harness, a new clutch pedal and a 2006 Triumph Speed Triple plastic fuel tank. Hopefully I don't have to cut the frame up to much to fit it. So wants the wiring harness comes in I will do a compression test. I have inspected the cylinders with my borescope and they look clean. The oil looks clean and the carbs look clean but I plan to rebuild and rejet them. I will be going from there as the engine determines the course of the build.

With all that said The build is going to start off very slow I have a lot of projects I need to finish before I get to this one.

So here is the bike all loaded up for its trip home.

IMAG1374 by jarrod vanwinkle, on Flickr

Here it is back home.

IMAG1375 by jarrod vanwinkle, on Flickr
IMAG1376 by jarrod vanwinkle, on Flickr
IMAG1377 by jarrod vanwinkle, on Flickr
IMAG1384 by jarrod vanwinkle, on Flickr
IMAG1395 by jarrod vanwinkle, on Flickr

I left the bike in the truck and the next I took it to get the title transferred over.

So yesterday I unloaded the bike I don't have bike ramps yet, I browed the sellers ramps to load the bike. So I used the engine hoist to lift the bike out.

IMAG1404 by jarrod vanwinkle, on Flickr
IMAG1405 by jarrod vanwinkle, on Flickr
IMAG1406 by jarrod vanwinkle, on Flickr

I got the bike cleaned up for the most part.

IMAG1408 by jarrod vanwinkle, on Flickr
IMAG1407 by jarrod vanwinkle, on Flickr
IMAG1409 by jarrod vanwinkle, on Flickr

Its new home for now.

IMAG1410 by jarrod vanwinkle, on Flickr

So I was hoping I could patch the tank up but it's way too far gone.

IMAG1415 by jarrod vanwinkle, on Flickr
IMAG1416 by jarrod vanwinkle, on Flickr
IMAG1422 by jarrod vanwinkle, on Flickr
IMAG1419 by jarrod vanwinkle, on Flickr
IMAG1420 by jarrod vanwinkle, on Flickr

And how it sits till the parts come in.

IMAG1430 by jarrod vanwinkle, on Flickr

[cbrfxr67]

Sweet garage!  Cant wait to see your progress!  sub'd for sure on this one!

[jarrodblake]

Sweet garage!  Cant wait to see your progress!  sub'd for sure on this one!

Thanks Progress may be slow.

I did a quick MS paint photoshop of the look I am going for on this build. The seat may end up a bit different but it's an idea. I was also thinking of making the rear seat frame removable with tabs letting me run a full size seat or a small seat or even have one of the seat frame made that has places to mount side storage of some kind. Just an idea I have been kicking around.

gs500e moto by jarrod vanwinkle, on Flickr

[gregjet]

You may be well disposed ( er...pun?) to chuck that tank and get a better one. As I have found on my project bike, once these tanks start rusting you can't stop them. You should be able to get a decent, or at least better one, cheap enough.
I have sanded rust converted and repainted it twice and it is bubbling under the paint again.

[alpo]

Steel is steel. Clean, prep, prime paint.

[jarrodblake]

Well I will never have to deal with a rusty gas tank on my GS500 ever again. My 06 TRIUMPH SPEED TRIPLE 1050 plastic tank came in yesterday. It's a bit wider than I thought it was going to be. I was hoping it was going to be narrower than the GS tank. But it doesn't matter as I was planning on modifying the frame anyways.

Here is the tank setting on the bike

IMAG1449 by jarrod vanwinkle, on Flickr

I will need to make a filler panel out of steel that will do here.

IMAG1447 by jarrod vanwinkle, on Flickr

I found a set of spray paint caps that fit perfect on the carbs.\

IMAG1450 by jarrod vanwinkle, on Flickr

There is a huge cavity under the tank for the Triumph air box. I am considering utilizing the space to mount my electronics under it as there is plenty of room. However my only concern would be the electronics would be mounted over the engine. I'm not sure if heat would be an issue or not.

IMAG1451 by jarrod vanwinkle, on Flickr

I have some 1/8 aluminum plate left over from a rat rod build. I think I have a big enough piece that I can make a fuel tank pet chicken mount that will go where the fuel pump was.

IMAG1452 by jarrod vanwinkle, on Flickr
IMAG1453 by jarrod vanwinkle, on Flickr

You can see here how much wider the tank is in spots.

IMAG1455 by jarrod vanwinkle, on Flickr
IMAG1456 by jarrod vanwinkle, on Flickr
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So my new 1990 wiring harness came in the other day. As will as my 08 shifter pedal.

IMAG1439 by jarrod vanwinkle, on Flickr
IMAG1440 by jarrod vanwinkle, on Flickr

obviously I would need to make mounting brackets or a mounting pan of some sort but there is more than enough room for everything in the tank cavity any thoughts on heat?

   IMAG1463 by jarrod vanwinkle, on Flickr

So today my new ignition switch and keys came in, as well as the 90 style Starter Solenoid came in so I got everything wired up and tested what I could. I have headlight high low, horn, the bike turns over and I have spark. I am hoping next week I will get it temporary fueled up and get it running. But before that I need to reshim the valves. I have good compresn in the right cylinder 150 psi but the left cylinder only has 50 psi. The bike has set for years I am hoping if I reshim it and get it running and up to operating temp I will get a little bit better compression numbers on the left cylinder. If not I will rebuild the top end. I hoping I can get over 100 psi on the left cylinder that way I can ride it and wait till winter to rebuild the engine.

IMAG1467 by jarrod vanwinkle, on Flickr

[jarrodblake]

Well I can't sleep so I made a few more photo shops

Here is V2 I cleaned up the seat mount and make it fit the gs frame better and added exhaust.

gs500e moto V2 by jarrod vanwinkle, on Flickr

Here is V3 I have seen a few GS's on Spoke wheels but I can not find what they came off of?

gs500e moto V3 by jarrod vanwinkle, on Flickr

V4 I made the seat shorter. I don't plan on having anyone on with me. The only problem is I can find a seat that short in this style. I'm thinking around 12-14 inches?

gs500e moto V4 by jarrod vanwinkle, on Flickr

[cbrfxr67]

Great pics!   I'd just not put the rectifier there.  Needs air and that spot is going to be toasty.  Other than that, create on!