2004 GS500F

[GarryGs500F]

hi my name is garry. I have had my 2004 GS500F for a while now. but sadly it was flooded in hurricane Harvey and i have been rebuilding it sense. it has been an awesome learning experience but i am stuck.  i have rebuilt the starter assembly completely.

i have gotten it to turn over but sadly there is no spark. i have purchased new ignition coils and a new CDI and installed them still no spark. i just replaced the wiring harness but sadly still no spark. im am at the end of my rope. i could really use some help from the notorious GStwins forum. i would be grateful. thanks 

[The Buddha]

That could be the crank trigger mounted on the right side under that round cover on the motor.
Or you could have a bad ground too, and in an electronic tach model, you could have some shorting in that circuit and likely affect the spark.
Cool.
Buddha.

[cbrfxr67]

where are you at sir?  wondering since you said 'harvey'







oh and where pics? 

[GarryGs500F]

i will get those pictures. i appericate yalls help!
and i am located in houston.

[cbrfxr67]

Gar hope you don't mind me documenting the fun,...

Yama can you rename this thread 'Turd of Turds?'  Ok just kidding,...not really

So got the honor of getting this beautiful example of gs craftsmanship running.  Any tips, instruction or condescending scrutinization welcome as always!


show look at this hotty


forgot to give me the key, that's cool, here's one out of basket case,...


what's that drip 


After side stand check, clutch switch, wiring,... ignitor, relay,...coils,... i think this is where the problem is.  Yes buddha already said that.    That's why he is the great one.  UNfortunately I couldn't find a SINGLE trigger close by so ordered from that place where the drop bears roam,....



To do,.... generator when it comes in,...oil leak, clutch lever, headlight, fix wiring, tiny led signals, paint, seat latch.  Prob more as we get into it.

[The Buddha]

A dealer can cut you a key with a code on the lock cyl.
Cool.
Buddha.

[ShowBizWolf]

I'm lookin!!!

[cbrfxr67]

Took another look at this one over the weekend and found,.. The bolt broken that holds the signal generator on.  It looks like someone used the wrong bolt and it rubbed on the cover until it finally broke.   This is why it backfired and would pop every so often but never start.


That broken bolt looks like it is going to be a real pita to get out.


Winning!  Not that hard.  This bolt was soft and easy to drill out with left handed drill bit.


After that, I used a good bolt and it cranked up on the first push of the start button. 

Got some tiny led signals,..


Turn signal relay was dead so I found a digital relay off an old scooter in the attic junk yard.

Mounted where I thought show would think they look hawt 


Playing with wiring and lights  oooh ahh

[cbrfxr67]

Wiring in headlight,..it's a led headlight.  I guess it looks ok.  Light output questionable.  Discolight works if you like that disco blue effect

[cbrfxr67]

bleeping wiring,... almost done with this mess though,....


vacuum hoses were 1/2 there so sorted that out and little high idle but better than it was


now it'll take a rev where as before it would die immediately

[cbrfxr67]

Picked up the right controls and that gave me the right connectors for the harness.  I don't know how some mismatched, spliced controls got on this bike but pita.

that must have been filmed with a flip phone



And said good bye to this old girl.  Good luck to Garrett and hope he has some great times on his GS

[yamahonkawazuki]

Ill rename it if the OP doesnt mind. Will let him make that call first.
Aaron

[cbrfxr67]

So, somehow this bike came back to me.  I guess I treated it well and it wanted to come stay in my garage.

Garrett dumped it with a zzr600 kwakasaki in my backyard a week or so ago.  Finally got some time with it yesterday.  This will be the thread of its story:

Both the kickstand and the center stand are botched.  I'm not sure how that happens but    I swapped on a center stand I had in the basket case. 

It seems like it runs ok but has no muffler and a terrible tapping sound coming from the head.  I'll put a stock muffler on it so I can hear it better.  Going to start with adjusting the valves and take a look in there.

After that I'm not sure what I'll do with it.  I'd like to rub a mad max fury theme on it.  Not sure,...

[cbrfxr67]

centerstand springs,.. kickstand springs,... center stand springs,...  kick stand springs,.. jiffy stand spring
For anybody searching how to get those springs on, I just wanted to insert this.  Brake spring pliers are a wonderful help unless you like cussing alot and fighting them.  Pretty sure HF sells them or any tool truck.  My .02

[cbrfxr67]

Finally got some time with this. Did valve adjustment, installed manual tensioner and checked starter clutch which looks ok. Put a stock muffler on it and can hear how bad it really is. Maybe this one is toast. Any ideas?