1993 re-hashed

[ShowBizWolf]

I find it soooo satisfying, making lists and then crossing things off like that. I've currently got a similar one going for a Sebring I just bought (I'm a Mopar gal )

Those shorter keys look great! I'll look into those when/if I ever need to make more for my bike.

[Sporty]

I find it soooo satisfying, making lists and then crossing things off like that. I've currently got a similar one going for a Sebring I just bought (I'm a Mopar gal   )

I built this 501 cu/in stroker for customer a few years ago.
It went into a 69 Dodge Dart and ran 9.71 at 144 mph the first time out.
  (No bragging, just sharing for the love of Mopars)

[ShowBizWolf]

That is fantastic!!!! You made my Saturday

[Sporty]

I've been working on this nasty old gas tank since the beginning of the project. It was rusty inside, the paint  was all scratched up, with chips to bare metal, and a few dents.

Just been poking at it here and there, spending a few minutes at a time. First the inside, the petcock. Then touch up, wet sanding.  Then finally tonight, buffing and trim.

The goal was just to make it usable and presentable for now.


Before any buffing

i







First time using Turtle wax "Clean Cut". It's actually quite good, on par with the pro stuff.




Don't spare the juice!




This is a very awkward tank to buff on the bench. A ratchet strap helped hold it down.






Looking a lot better! 
the original paint has a nice blue purple flake in it.




The gas cap came with the bike. It's kind of cool, CNC machined, We'll see how it works out.




Petcock installed




Trim installed.

[Sporty]

Spent a couple hours working (getting frustrated) with the K&N filter, and plumbing nightmare of fuel lines, breather hose, carb vent hose.
What was Suzuki thinking

The K&N seemed too small to fit onto the carbs. The number checked as correct. I think it was not on all the way, the  clamps tightend onto the rubber and  not positioned  over the the metal spigot of the carb, and that "shrunk" the filter. It was a lot of working and stretching to get it on and clamped. 




The "Visu-Filter " installed with new fuel line. If someone isn't familiar, the Visu-Filter is a 60 micron stainless screen in a rugged plastic housing. It can be blown out to clean. It's there to keep out anything big enough to clog up a jet.







Mocking up with the tank to be sure everything fits..

[Sporty]

I needed to test how much reserve this rehashed petcock would yield




Rigged up the tank level and poured gas in with a  "calibrated  " two liter bottle and was a little shy of two bottles (4 liters) before fuel began coming out the main feed. So about 3.6 liters useable reserve.



I had chosen 25.4 mm OD washers for the mount bolts that looked correct, but they rubbed the bracket. Had to drill out 5 x 22 washers for the job.



The tank is on, but has a gap under the front of the  moulding.

[SK Racing]

This is such a good thread. Don't know where you get the energy to do the work AND take photos.

I've been doing a bunch of work on my own bike, but took very few pics.

I can't wait for your next post. 

[Sporty]

Exactly two months after it came home, the thoroughly rehashed GS500E, gets its first test drive.

It runs and rides OK!
. Idles well around 1200, pulls good from about 5K RPM and up. Definitely a dog in higher gears at say 3k RPM. It should have plenty of pep for a new rider. It gets to 50 MPH quickly. I could not get much of a power wheelie (throttle only) in first gear, despite the new 15 tooth sprocket. Even with that sprocket, it needs some throttle and clutch from a stop. I'm thinking the 15t  was a good decision

The bike is way too small for me (for any lengthy riding). I hate the handlebars that I chose. The shifter needs adjusting down, the rear brake adjusting up. The brakes are already bedding in. The bike handles acceptably (from the short test ride)







3.7 miles on the first ride.



The big issue now is that it no longer starts from the handle bar starter button. I had to jump B+ to the yellow/green wire on the starter relay. 

So now I have to trace down and troubleshoot what I messed up!

[SK Racing]

Congrats on the first ride. 

I also went for a 15 tooth sprocket. Not to do wheelies, but to feel a little more "torque" at our high altitude. 16% less air density makes N/A vehicles feel spiritless.

The big issue now is that it no longer starts from the handle bar starter button. I had to jump B+ to the yellow/green wire on the starter relay. 

So now I have to trace down and troubleshoot what I messed up!

I know the feeling. For the past few days I've been rewiring my bike and made quite a few changes to the loom to relocate the electrics under the seat. Now the taillight doesn't work, but the brake light does. Aaaarghhh! 

[Sporty]

Congrats on the first ride. 

I also went for a 15 tooth sprocket. Not to do wheelies, but to feel a little more "torque" at our high altitude. 16% less air density makes N/A vehicles feel spiritless.

That's just my "power test".  It's prob good that a new riders first bike doesn't power wheelie.

It's actually pretty snappy around 7k RPM

The K&N makes a lot of noise, more so than the Cobra F1s.  It sounds powerful

[Sporty]

More buffing...

These won't go on yet.. still have to sort the bike out a bit.

Scratched and abused.






This one had a rattle can repaint except for the decals.




Using the small 3" buffer for this job. Turtle wax Clean cut first, followed by the Meguiars swirl remover.

[Sporty]

After warming up the engine, the oil was drained and filter replaced.

The old oil had an odor of gasoline.

Oil filter inspection.  Cut the end of the pleats with a razor knife or hack saw.  (Don't cut into the inner metal tube.)

A section of the pleated media squeezed in the vise to get rid of excess oil.



Spread out the media and inspect.





A fair amount of metal trash in the filter media.




The trash is magnetic (steel or iron) Since the transmission, clutch, starter drive and engine share the same oil and filter, the steel could be from any of those components. My suspicion is transmission related since there are no unusual engine noises and the oil pressure light isn't on at hot idle.




The steel (or iron) debris stuck onto a small pocket screwdriver magnet.




I have no idea how old the oil and filter were, or how the bike was ridden before.

It will be interesting how the oil filter looks a the next change.

Anyone else think oil filter quality is important?

[mr72]

fwiw with a 14t sprocket and the suspension and riding position mods (which make a difference), my GS will barely pull a tiny wheelie in first pulling away from a stop at wot if you lean back just a little. It is extremely interactive at >50 mph though. I was initially on the fence about 14t until the 150/70 tire went on the rear which makes it basically perfect. gps tells me the speedo actually reads a bit slow with the 150, so that tire ups the gearing, I think it is similar to stock tire and a 15t.

Sluggishness under 5k rpm could be float height or maybe needle shimming. I wound up with two washers on mine to get it properly sorted.

[cbrfxr67]

such a great thread!  Congrats on first ride!  Milestone reached!

[Sporty]

fwiw with a 14t sprocket and the suspension and riding position mods (which make a difference), my GS will barely pull a tiny wheelie in first pulling away from a stop at wot if you lean back just a little. It is extremely interactive at >50 mph though. I was initially on the fence about 14t until the 150/70 tire went on the rear which makes it basically perfect. gps tells me the speedo actually reads a bit slow with the 150, so that tire ups the gearing, I think it is similar to stock tire and a 15t.

Sluggishness under 5k rpm could be float height or maybe needle shimming. I wound up with two washers on mine to get it properly sorted.

Thanks.

I've never ridden a good running GS500 to know what its like.

I jetted and set needles based on the "Jet thread" (40/140/one washer/ two turns with K&N/ Cobra slip-on)  but it would be optimistic to expect to hit it on the money first time.

The vacuum petcock is leaking a little into the vacuum line. The kit just came in so it will be repaired and test ridden again.

[mr72]

oh I didn't know about the k&n. Sluggishness in mid-range might be normal.

[Sporty]

such a great thread!  Congrats on first ride!  Milestone reached!

This is such a good thread. Don't know where you get the energy to do the work AND take photos.

I've been doing a bunch of work on my own bike, but took very few pics.

I can't wait for your next post. 

Thanks. It's been a lot of work. Way more than expected.
The photos are easy tho, snap a few with the iPhone as I'm working. Upload and a brief write up before bed or at a break. The updates have helped motivation  to finish.
The forum resources and wiki are invaluable!

[ShowBizWolf]

Last time I changed the oil and filter (and oil pan gasket and cleaned the screen) I installed one of those magnetic drain plugs. Dunno if that'd be of interest to you but I figured I'd mention it.

Tank looks GREAT and so do the tail plastics! I remember the first time I noticed the bit of blue metallic flake in the black paint... it's a nice touch IMO.

[Sporty]

I was too busy to work on the bike last night, but did look at the wiring diagram. (For the No crank issue)

It looks as the starter relay pull in circuit is just the clutch and starter switch. It worked before messing with things, so it's time to back to were the work was done inside the headlight
The yellow/green connection for the clutch switch is sticking out as a place to check.  If not the problem, the headlight wiring is a good place to make some meter tests.

[cbrfxr67]

really interested to see how you do with that k&n.  It was challenging for me, so be great to see you nail it with no problems!