Maintenance list, help with prioritising (anything I'm missing)

Started by HerpityDerp, October 15, 2017, 08:48:40 PM

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HerpityDerp

Hi All,

Firstly a huge thanks and apologies to:

Watcher
1018cc
ajensen

for taking the time to reply to my thread

http://gstwins.com/gsboard/index.php?topic=71911.msg865412#msg865412

and I honestly got side-tracked with work which is why I didn't reply (short answer yes the slack was much larger than 3/4" I got it checked but I can't remember the exact amount of play, just that it was greater). 

Secondly I've really had enough of the paranoia, rattles, skips and otherwise things sounding super out of place.  As I have said in my past ticket, it's my daily ride (no car etc.) and I really don't have the resources to get a mechanic to look it over (forgetting the money but the time off work etc.) so I've been getting an itemised list for myself.  Therefore without further ado; my current parts list:

Model - 2009 GS500f
KMs - 50500

Stage 1 - Drive and Brakes

http://www.ebay.com.au/itm/2004-2014-Suzuki-GS500F-XAM-x-ring-chain-and-MTX-steel-sprocket-kit-16-39/232285140399?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/Profi-CAT-laser-dot-chain-belt-alignment-tool-motorcycle/231359659680?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/Suzuki-Genuine-GS500-2004-2007-Brake-Disc-Front-59210-01DA0-000-/321249220182?hash=item4acbf21656:g:~x0AAOxygj5Sg5tm

http://www.ebay.com.au/itm/Suzuki-Genuine-GS500-2004-2007-Brake-Disc-rear-69211-01DA0-000-/321249216006?hash=item4acbf20606:g:2gsAAOxygj5Sg5nV

http://www.ebay.com.au/itm/MetalGear-Brake-Pads-Rear-SUZUKI-GS-500-E-GM51B-1988-1995-/162120520194?hash=item25bf22d202:g:tScAAOSwRLZT-7np (Will be getting the front as well)

Reason - I believe that the alignment might have been out at some point and has caused a degree of wear on the teeth so will change them over with the rear tyre, the rear brake is squealing slightly if i haven't hit the brakes in a while (and it looks like there are a few slight grooves there), same with the front.  The front sprocket is making a clicking noise if I oil the chain as well, not sure if it's because of grit or if the front sprocket teeth are catching on the sides of the chain.  The previous owner has put a cheap stubby lever set including master cylinder (for which the bracket has snapped) so I need to find a replacement set of levers and brake master cylinder. 

Alternatively I could take the brake rotors off this or keep the old ones and put new pads/fluid in:

http://www.ebay.com.au/itm/SUZUKI-GS500-WHEELS-AND-TYRES-BRISBANE/232342439630?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

Second Stage - Cam Chain/Valves

http://www.ebay.com.au/itm/Suzuki-VALVE-SEALS-seal-gs1000-gs850-gs750-gs650-gs550-gs500-gs450-gs425-intake/391889345006?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/GS400-GS425-GS450-GS500-GS650-GS700-GS750-GS850-GS1000-GS1100-GS1150-Cam-chain/361768709290?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/NEW-14-Suzuki-29-5mm-Valve-Shim-Assortment-Variety-Shims-Lot-2-30-to-3-00/162373668717?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/Suzuki-GS500-E-twin-Motion-Pro-valve-shim-tool-new/272848382717?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

Reason - I really have no idea if it's up to scratch or not, my biggest fear is that it's either out of spec and I don't have the parts to fix it or I leave it and cause more issues for myself. The throttle response is seemingly more sluggish. 

Stage 3 - Carbs/Clutch

http://www.ebay.com.au/itm/2006-SUZUKI-GS500-CLUTCH-ASSEMBLY/321370402906?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649 (In truth I'll probably get new friction plates and springs).

http://www.ebay.com.au/itm/Dual-Gauge-Motorcycle-Motorbike-Carburetor-Synchronizer-Tuner-Tool-2-Cylinder/171868202233?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649 (Not sure how to re-tune the carbs after repairing)

http://www.ebay.com.au/itm/Suzuki-GS-500-F-K5-GM51A-Faired-2005-Full-Gasket-Set/302066038561?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649 (because I can count on myself to wreck a gasket in the process)

http://www.ebay.com.au/itm/2X-Carburettor-Repair-Kit-Suzuki-GS-500-2004-2006/332165798023?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

Reason - The throttle response is seemingly more sluggish which makes me believe that there could be excess buildup of resin (I only run 98 V-Power) and the idling seems off too, bike doesn't seem to be able to run at low revs anymore without stalling and have to maintain a 4k range just for stop-start in traffic.  In addition a choke start after a short break doesn't work quite as well and the symptoms seem very similar to flooding.  Prior stubby levers are affecting the clutch as well as it seems to get looser and looser (replaced the clutch cable less than 2000kms ago, went from tight to a lot of play in a few weeks). 

Stage 4 - Aesthetics

http://www.ebay.com.au/itm/Throttle-Tube-and-Grip-SUZUKI-GS500-GS500F-GS-500-2013-13-GET-IT-FAST/192280287193?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/SUZUKI-GS500-RIGHT-switch-gear-BRISBANE/232256459836?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/SUZUKI-GS500f-switch-gear-LEFT-BRISBANE/232164109230?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/SUZUKI-GS500-GS-500-Set-of-2-Exhaust-Gaskets-2-New-Gasket-2000-2009/262465353938?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649

http://www.ebay.com.au/itm/Suzuki-GS500-GS-500-2010-Seat-Genuine-OEM/162615510630?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D1%26asc%3D20140205102603%26meid%3D52cf4c3c9c254fe1b8a1d48a3c1b34b3%26pid%3D100022%26rk%3D4%26rkt%3D4%26sd%3D192280287193&_trksid=p2055119.c100022.m2048

Reason:  Being out in the sun the bike plastics and seat are starting to show signs of age, so this is to get it back to a good condition, the seat is starting to crack and wear so will be changing that out as well.  When I accelerate there is a high-pitched whistle that comes from the bike which I can't put my finger on but I am thinking just change over the exhaust gaskets while the bike is in pieces. 

Tools I am getting the special shim removal tool but also either a Clymer or Haynes manual....not sure which one to get.  I also need to assess the wiring as the odometer is playing up (tacho is resting at 0 while the bike is revving and doesn't change until you flick the front, same with the speedometer), and the indicator bulb might have blown (indicators work, but the light on the panel doesn't) and I need to find out where to start to fault find. 

At the end of the day - money is a necessary consideration in that the speed by which I can fix things is affected by how expensive a repair job is.  If anyone has any suggestions or maybe things I can avoid (maybe by the sounds I should be focusing on a certain area rather than the ones I've mentioned) it would be extremely appreciated.  Thanks to all and hope you have a great day. 

Herpity Derp


Sherpa and Derpa....for da HerpityDerpitySherp

J_Walker

From a quick glance. you have valve seals posted under cams, but then you have a whole engine gasket kit, that comes with valve seals, so take off the solo valve seals and use the ones that come in the engine gasket kit.

edit; same as the exhaust gaskets you have below, they are in that engine gasket kit.

edit 2; not sure you really NEED the whole clutch plate housing. replacing the padded plates, themselves should be fine however I have not followed your build. maybe replace the steel ones too, but only if they are warped or blued.
-Walker

gruntle

get a spare clutch lever and tuck it under your seat - you'll want to kiss me when you need it!
:wink:

HerpityDerp

@J_Walker - whoops, that was a slight oversight on my part.  Gasket kit would be all I'd get.  I tried looking at one of the forum posts regarding Haynes vs. Clymer but it seems to have been taken down or broken link? So from a perspective of someone who would need a lot of visual aid and more laymans explanation than some youtube videos, which would you recommend? Also the Clymer only seems to go to 2002 GS - from memory there's no difference from 2002 onwards yes?

@gruntle - I've actually been thinking about putting a kit together for just such an emergency.  My mate who had a Yamaha XJ6N had a buttload of stuff in his seat....have no idea where to stash it for mine, call me crazy but I look at the cavity under the seat and I don't think it would fit.  Or am I missing something??
Sherpa and Derpa....for da HerpityDerpitySherp

gruntle

Have a rummage under the tail - there's a surprising amount of room there. I use ziplock bags with rags to pad and stop rattling and carry an ever growing range of stuff - pretty extensive range of sockets and spanners (wrenches to you 'Merkins) together with 2 sizes of ratchet socket handles, screwdrivers etc.

Old school tip - spare spark plug (doesn't matter if old as long as it's a known working one) - and very definitely a decent plug socket - ever tried to get a spark plug out with that pathetic tin thing and bendy handle that (might have) come with the bike?

Briefly, imagine a cold, wet, pitch black night in the middle of nowhere and a 20 mile walk to the nearest petrol station when you've just had a puncture or the engine died.....  :sad:
Minimum are tools required for front/rear wheel removal (and subsequent replacement) in case of puncture, plug socket and bar (to check that a spark is actually there), TORCH (because it's a dark and windy night....), rag/wipes to clean oily mitts before sticking thumb out to hitch a lift to wherever with a punctured motorcycle wheel under your arm, spare fuse, length of wire for bypassing anything, zipties (s,m.l sizes), string, plastic disk for side stand on soft ground... and the list goes on...
:icon_eek:

HerpityDerp

Quote from: gruntle on October 18, 2017, 04:15:33 PM
Have a rummage under the tail - there's a surprising amount of room there. I use ziplock bags with rags to pad and stop rattling and carry an ever growing range of stuff - pretty extensive range of sockets and spanners (wrenches to you 'Merkins) together with 2 sizes of ratchet socket handles, screwdrivers etc.

Old school tip - spare spark plug (doesn't matter if old as long as it's a known working one) - and very definitely a decent plug socket - ever tried to get a spark plug out with that pathetic tin thing and bendy handle that (might have) come with the bike?

Briefly, imagine a cold, wet, pitch black night in the middle of nowhere and a 20 mile walk to the nearest petrol station when you've just had a puncture or the engine died.....  :sad:
Minimum are tools required for front/rear wheel removal (and subsequent replacement) in case of puncture, plug socket and bar (to check that a spark is actually there), TORCH (because it's a dark and windy night....), rag/wipes to clean oily mitts before sticking thumb out to hitch a lift to wherever with a punctured motorcycle wheel under your arm, spare fuse, length of wire for bypassing anything, zipties (s,m.l sizes), string, plastic disk for side stand on soft ground... and the list goes on...
:icon_eek:

Nice, ill have to have a look tomorrow, as far as the tyre repair I remember seeing (for small punctures only) these small barbs that you punch into the tyre then twist off the top and off you go, can't seem to find them but they were a little less messy than the strips, glue and handle to be honest, though I don't think they're as durable...very emergency/temporary only.   

As far as the rest, I honestly hadn't considered a spark plug - my usual thoughts when it comes to kits is things like tyre repair, chain links and such (I've been very fortunate in not having had any major problems *knocks wood......many times*). 
Sherpa and Derpa....for da HerpityDerpitySherp

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