Author Topic: 1996 GS500 Basket Case Build into a GS600R  (Read 120377 times)

Offline cbrfxr67

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1996 GS500 Basket Case Build into a GS600R
« on: April 12, 2011, 09:54:10 PM »


I picked up my first GS500 last week.  This is the first Suzuki I've had.  The motor had a bad rod bearing and PO decided to dismantle the whole engine.  I'm still deciding whether to get a replacement engine or try and put this one back together.  I'd like to use this post to document my progress and get feedback from the GREAT forum here at GSTWINs.  This forum is really well mannered and informative.  I've been on cbrforum.net and of course customfighters.com for quite awhile now but I'm really enjoying reading the 1200something pages of posts here!  I'm working on posting pictures right now and will continue to do so as the build goes along.  I'm from Houston and here's a 'hello' to all the people at GSTWINs.

« Last Edit: October 09, 2017, 03:53:11 PM by cbrfxr67 »
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #1 on: April 13, 2011, 12:56:42 AM »
So today I test fit an old F2 engine.  I have an F2/3 that I've been learning on for the past few years.  Then I picked up another on the cheap and fixed it also.  With all of the cbr parts I have, I thought I could find another but somehow I ended up with a GS500.  Obviously, I'd try to insert cbr600 engine right?!  For people searching to see if this will work: nope.  Not without modifying the front frame for the exhaust.  The rear wasn't too bad and you could fab some brackets but the exhaust was the dream killer.  So, back to my gs500 engine.  PO didn't give me the piston assembly, so I'll have to locate that before I can start putting things back together.
« Last Edit: October 09, 2017, 03:54:22 PM by cbrfxr67 »
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #2 on: April 13, 2011, 01:11:30 AM »
Messing around with more F2 parts.  Probably way too big for this bike.  You know how it is when you don't have anything to do without parts and you start going 'hmmmm' and looking around the garage. 
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline BaltimoreGS

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Re: 1996 GS500 Basket Case Build
« Reply #3 on: April 13, 2011, 01:33:55 AM »
If I remember correctly, the CBR rear sets will fit if you use a bolt with a smaller head.

-Jessie

Offline Twisted

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Re: 1996 GS500 Basket Case Build
« Reply #4 on: April 13, 2011, 07:59:47 AM »
Welcome to the forum CBRFXR. Keep us updated how you go.

Offline tb0lt

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Re: 1996 GS500 Basket Case Build
« Reply #5 on: April 13, 2011, 02:35:33 PM »
Is this the red $600 gs that was on Houston CL last week? You bought it from Jake?

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #6 on: April 13, 2011, 06:58:28 PM »
Yes that's right.  Nice to see fellow Houston rider here!  :)
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #7 on: April 15, 2011, 04:10:08 PM »
Any opinions on trying to stuff that 600 motor in there?  I'm having a hard time finding a replacement engine that doesn't cost more than the whole bike.  I'm even having a hard time finding a piston/rod assembly to try & rebuild my old one.  Anybody got one lying around?  :dunno_black:
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline tb0lt

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Re: 1996 GS500 Basket Case Build
« Reply #8 on: April 15, 2011, 04:18:57 PM »
Any opinions on trying to stuff that 600 motor in there?  I'm having a hard time finding a replacement engine that doesn't cost more than the whole bike.  I'm even having a hard time finding a piston/rod assembly to try & rebuild my old one.  Anybody got one lying around?  :dunno_black:

I vote for the 600 install into the GS frame. It would be cheaper than a proper rebuild of your old motor. You will end up with a really unique and SUPER fast GS :)

Offline BaltimoreGS

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Re: 1996 GS500 Basket Case Build
« Reply #9 on: April 16, 2011, 12:12:58 PM »
As narrow as the GS frame is won't it be hard to get the final drive to line up correctly (assuming stock swing arm)?

-Jessie

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #10 on: April 18, 2011, 01:57:53 PM »
Most of Saturday I worked on aligning and setting the 600 engine in the frame.  I took a boat load of pictures but jacka** phone isn't cooperating on downloading them.  I'll have to get my digital camera and do it that way.  The mounting points were, of course, way off so I began making jigs to hold the engine while I weld in new tabs.  Basing the position on: making the carbs fit on top and making sure the sprocket/chain line up on rear, I bolted in some hangers.  I'm trying not to cut out/modify the original frame & mounting points as much as possible in case at one point we retro back to the gs engine.  The engine itself fits easily in the space and doesn't touch the frame at all.  The carbs fit, right before the bends in the frame under the tank.  The removable frame piece doesn't want to fit because of the engine mounting tab, which hits the oil pan of the f2 motor.  I'll have to figure out what to do there later.  All in all I was happy that this seems like a doable project.  Pictures to come.  Any suggestions, tips or advice is well appreciated.  :icon_idea:
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline The Buddha

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Re: 1996 GS500 Basket Case Build
« Reply #11 on: April 18, 2011, 02:05:22 PM »
If I were you, I'd fab up an exhaust that will clear the frame, there are people who can do anything with muffler pipe.
Cool.
Buddha.
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Offline scottychop

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Re: 1996 GS500 Basket Case Build
« Reply #12 on: April 18, 2011, 03:17:04 PM »
Can you make the engine a stressed member of the frame?  Cut the left side to match the right and make two upper mounts. 

Offline jeffdodge

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Re: 1996 GS500 Basket Case Build
« Reply #13 on: April 18, 2011, 04:09:13 PM »
I would LOVE to see that. If it can be done, being that the GS frame is just steel, I may have to attempt this down the road.

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #14 on: April 19, 2011, 02:16:49 AM »
Tonite only had time to mock up one bracket and weld it in.  Still having problems with my pics but I'll get some tomorrow.  Not enough time & energy in the day!
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline the mole

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Re: 1996 GS500 Basket Case Build
« Reply #15 on: April 19, 2011, 06:11:19 AM »
I'm trying not to cut out/modify the original frame & mounting points as much as possible ........ The removable frame piece doesn't want to fit because of the engine mounting tab, which hits the oil pan of the f2 motor.
Cut out the mounting tab, you can always get another removable frame piece if you go back to the GS motor again later.

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #16 on: April 19, 2011, 02:59:06 PM »
Finally got my phone to cooperate somewhat.  Here's my work space, with the GS, an F3 I reworked, and my cn250 rat. Another pic of workspace Of course one of my main concerns was making sure the carbs would fit in the frame and line up correctly. Got carbs? That's all I got for now.  Will work on welding more tabs in tonight and try to make some more progress
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline The Buddha

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Re: 1996 GS500 Basket Case Build
« Reply #17 on: April 19, 2011, 04:20:10 PM »
Ooooooo ... engine-swap-gasm. Man that baby fits in there like it was made for it.
Looks like my acheivement of the weekend (fitting a buell blast tank on a GR frame) now is just to be thrown by the side of the road man.
Cool.
Buddha.
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Offline jeffdodge

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Re: 1996 GS500 Basket Case Build
« Reply #18 on: April 19, 2011, 05:12:42 PM »
Looking amazing. Cant wait to see it done.

Offline cbrfxr67

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Re: 1996 GS500 Basket Case Build
« Reply #19 on: April 20, 2011, 01:20:15 PM »
Ooooooo ... engine-swap-gasm. Man that baby fits in there like it was made for it.
Looks like my acheivement of the weekend (fitting a buell blast tank on a GR frame) now is just to be thrown by the side of the road man.
Cool.
Buddha.
Buddha please honor me with a pic of that buell blast tank you did!  :bowdown:
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha