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2005 GS500F | Scrambler Project

Started by Joester41, September 10, 2015, 06:26:36 AM

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Joester41

Hey all, just picked up a 2005 GS500F as a scrambler/tracker project bike. Needs some carb work but runs good otherwise.

What are the K&N lunchbox P/Ns that are compatible with this bike?

What are your recommendations for a header/exhaust replacement/enhancement?

What websites do you recommend for OEM parts (like the headlight assembly and bracket for the GS500E model)?

Do Suzuki dealers still offer part support on 10+ year old bikes?

Thanks in advance for any info on these topics. I'll be posting up pictures of my build as it progresses.
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

squrit_air

As far as I know the bike has barely changed over the 20 years they made it. MOST part work across all of the models. Bike bandit had all the parts on mine, and the dealer near me could order all the parts as needed for my bike, an 09gs500f. The light bracket they do have on bike bandit. For the header and exhaust, someone made a system. As far as I know k&n doesn't make a box for it, but other builds have different filter that a OEM replacement.

akapellen17

The K&N part number is RU-2970 for the lunchbox filter. I have a delkevic exhaust and I love it! (Much cheaper too) but there is also yoshimura and jardine. If you are already cleaning the carbs then it's pretty easy just to swap the jets to fit the air filter and new exhaust. Either way, the K&N air filter will require a rejet
2005 Suzuki GS500F
Race Tech Springs | R6 Shock | GSXR Rearsets | Delkevic Carbon | R6 Throttle | Gauge LEDs | Dash Clock | ZG Double Bubble | Chuck81's Fork Brace | Gold D.I.D. Chain | GP Shift | Katana Rear Wheel | Battlax S20 Evo | SV650 Clutch and MC | Braided Brake Lines

Joester41

Thanks for the info!

Ordered the K&N lunchbox and a stainless delkevic system. Will also be ordering the Mikuni jets tonight 20/65/142.5.

Has anybody had success using universal flasher relays for LED turn signal conversions? I've done this on another bike by just replacing the turn signal relay with a universal LED one, didn't have any problems.

Are there any manufacturers making aluminum throttle tubes that will bolt up without modification? Looking for one without the lip that tucks under the grip.
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

squrit_air

Get some R&G turn signal delays from revzilla, I just hid them in the tail.

Get the 21.5 Ohms
http://www.revzilla.com/motorcycle/rg-racing-turn-signal-resistors

akapellen17

I have an r6 throttle tube on my bike. It takes less of a turn to go to full throttle. There is a thread somewhere on here about it. I'm sure some company makes an aluminum throttle for the r6
2005 Suzuki GS500F
Race Tech Springs | R6 Shock | GSXR Rearsets | Delkevic Carbon | R6 Throttle | Gauge LEDs | Dash Clock | ZG Double Bubble | Chuck81's Fork Brace | Gold D.I.D. Chain | GP Shift | Katana Rear Wheel | Battlax S20 Evo | SV650 Clutch and MC | Braided Brake Lines

FTL900

The last flasher I replaced was on a Suzuki Bandit 600 and it was direct plug and play. 
I think the one bike (Superhawk maybe) that wasn't a direct fit required me to change one wire or something... I don't recall, but it was easy. 

I just got a new flasher in the mail yesterday from SuperBriteLED for my Bandit 1200 project. 
I change the flasher on most bikes I work on so I don't have to think about turn signal types anymore, I can just use anything.
ZRX1100, Bandit 1200S, GS500, EX500

Joester41

I've been slacking on my build updates,here is what it looked like the day I picked it up...







Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Joester41

Some more pics after the fairings and some other parts removed.







Delkevic exhaust fit-up.



Custom skid pan and headlight brackets.




The frame has been chopped, getting the loop welded tomorrow. I will also be bead blasting the skid pan and center headlight mount tomorrow. Stay tuned for more pics.

Not shown in the pics, K&N lunchbox and breather, designing a custom batterybox and some other components yet.
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Daeouse

#9
You sold the fairings and light, didn't you? I'd kill for those. . . I've been scoping the Airstream fairing kit. . .

*shifty glance* Still have it? ;)

Nice work, by the way. Looking forward to seeing where this goes. . .
Jon "MotoSquirrel"
2009 Yamaha V-Star 950
My Blog!

Joester41

Quote from: Daeouse on November 19, 2015, 05:16:20 PM
You sold the fairings and light, didn't you? I'd kill for those. . . I've been scoping the Airstream fairing kit. . .

*shifty glance* Still have it? ;)

Nice work, by the way. Looking forward to seeing where this goes. . .

Actually, I still have the fairings and all the hardware...
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

UCFjeff

I like where this is going. What size tires are those?

Joester41

Skid pan and center headlight bracket done..




Got the rear loop done and the remaining brackets chopped, just need to clean up the residual welds from the brackets.


Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Joester41

#13
Quote from: UCFjeff on November 19, 2015, 06:49:38 PM
I like where this is going. What size tires are those?

120/70-17 front, 130/80-17 rear, continental TKC80s
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Daeouse

Jon "MotoSquirrel"
2009 Yamaha V-Star 950
My Blog!

mihkels

Looks great.

Waiting for updates as I'm thinking about a similar build during the winter.

lucas

Hi, where did you get the clamps mount your headlight to the front forks?  Did you make them?

Joester41

Quote from: lucas on November 23, 2015, 01:42:23 AM
Hi, where did you get the clamps mount your headlight to the front forks?  Did you make them?

Yes, I made them. Designed them in CAD and had a local shop laser cut and form them.

The clamping parts that attach to the fork are from a generic bike master headlight mount.

I also had to make the center mount for the JW Speaker headlight bucket, it was a 3 hole mount, not the 2 hole with the square clocking features.
Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

mihkels

Any updates on this? I'd like to see what plans you have for the seat and the tank.

iamhiding

loving the skidpad/sumpguard, thats a cool touch. end of the subframe is looking sweet as well.
current project list:
//cbr 600 f3 fighter
//gsxr 1100 mental oldskool supersport
//gs500 daily rat tracker cafe fighter that changes every couple of month... cafe fighter?

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