GStwin.com GS500 Message Forum

Main Area => Projects / Builds, Racing and Tech => Topic started by: bombsquad83 on February 12, 2012, 09:53:35 PM

Title: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on February 12, 2012, 09:53:35 PM
Well...my question in the General Area was turning into more of a build thread, so I thought I would move on to here.  Plus now I have pictures :).

I got my 1993 GS500 back in August last year, and I've been working on it ever since.  I've done a lot of work to refresh it from it's neglected state. 
EDIT: Forgot to mention she only has 6,3xx miles :).

As I said in my other thread, I've done a lot of work already.  It started out with a 145 main jet, so I'm thinking the previous owner had a lunchbox or something on it.  Exhaust seems stock.  I'm now running the stock airbox with a new OEM filter and 125 mains and 40 pilots, 3 turns out.  I discovered it already had progressive springs when I did the fork seals.

Update 3/26/12
Running very weak in the left hand cylinder.  LH cylinder dies with choke, this explains the RPM with choke issue.

Update 4/1/12
Rode it around town for 35 miles today.  Runs great once it's warmed up.  I think it's too rich at idle on the left hand cylinder.  Gotta review my carb work.

Update 5/5/12

Fixed my one cylinder choke issue by cleaning the starter fuel jet at the bottom of the float.  Tried again to fix the gas level issue in my float bowls.  Cleaned my old needle valve seats and replaced the new ones that came with the kit.  Several tries at adjusting the float height yielded decent results.  I will be checking my plugs for richness periodically until I'm happy with it.

Update 6/8/2012

Finished the paint, decals, new grips, and tank protector.  Pictures on Page 4 of this thread.

The finished product:
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Ff3a20c60.jpg&hash=0a0604a7a9b2334a1821fe5ccb41d1d8bf1c2fc6)

List of things I've done

Carb work
Thorough cleaning of the carbs and replaced all the jets (125 mains, 40 pilots, 1 washer)
Replaced old parts with new OEM jet needles and needle jets, o-rings, gaskets, needle valves, and diaphragms
Replaced Gas seals and T connectors (requires splitting the carbs)
Measured and reset float heights (measured, and checked with clear U-shape tube method)
Replaced all JIS screws on the carbs with SS Socket head cap screws
Made cheap differential monometer and synced carbs

Regular maintenance
changed oil and filter (each Spring)
new OEM air filter
Put on new chain and front sprocket (RK X-ring chain, JT 15T sprocket)
Valve Clearances checked and intake shims replaced, exhaust shims swapped left to right - broken bolt and stripped threads fixed along the way see http://gstwins.com/gsboard/index.php?topic=58463.0
Mounted new tires, Pirelli Sport Demon in stock sizes (110/70 F, 130/70 R), and another new rear at 9,500 miles
new battery (guy had one that was too tall and vented on the wrong side...doh!)
another new battery at 9,500 on 5/1/2014 - MotoBatt MBU10 AGM battery
Fork seals 2x - Originally overfilled forks to 99mm
15W fork oil used - filled to 130mm from the top of the tube for Progressive Springs
Replaced one left fork tube due to continuous leaking problems
Replaced all fuel lines and all other hoses (water drain and breather hoses were missing)
Flushed Brake Fluid
Cleaned Gas tank cap vent
Replaced all the missing bolts

New OEM Parts
Used OEM Bar-ends (non present before)
New choke cable
Replaced Brake Lever
Replaced Clutch Lever
Replaced Clutch cable adjuster on the lever side
Replaced Dampers for Tach and Speedo
Replaced one Front Turn Signal Lens
Added all stock reflectors that were missing

Projects
Replaced vacuum petcock with CRF250X petcock (ground down as shown in other threads)
Tank Cleaned out and sealed with POR-15
Cleaned up and repainted battery box
Urethane professional grade automotive paint (Blue Metallic)

Aftermarket Parts/Upgrades
Bikemaster GP Touring Chrome Handlebars
Rear signals (smaller short stalk)
Pro-Grip Gel Grips
Pro-Grip Tank Protector
Hayabusa style Rear pegs to replace stock front pegs (shorter rubber pad for leg room)
Used SV650 front Caliper with OEM HH pads
HEL stainless steel front brake line
MotionPro SV650 style throttle tube (shorter turn)
Hyper-Lites Superbright LED Flashing Brake Lights

To be done
Modified and recovered seat - In progress
HEL stainless steel rear brake line
09' GS500F Stock Rear Shock

-----------------------------------------------------------------------------
Here's a picture of how she sits right now...
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1048.jpg&hash=43e1029b1b02256ba529250cbdf32417e9255c15)

Today I worked on the tank and prepping the plastics for paint with a buddy of mine.  The tank had a coating of grey stuff that is probably Kreem or something that was flaking off pretty badly.  It also has a big dent a few smaller ones that are needed filling.  Here are some before pics...
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1029.jpg&hash=fcb7cdfc8bbd1b8d3b1e0dccea23f5efde58aacf)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1040.jpg&hash=d3bc66e27c52def5ab6dbf18433bb97de9ff63b2)
Junk on the petcock
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1028.jpg&hash=9adea3cbde9cdf97d91d98cc6f7c308cd7c4ac01)

Tried putting an old chainsaw chain in there and shaking it around.  Some of the coating came out like wet leaves, but not all of it.  More work to do here...any suggestions?  Need to look around the forum at what others have done some more.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1043.jpg&hash=3e5ae682502a961f72d69b7ade54a4f5b5cc03e0)

Here are the plastics before prep.  Some scratches needed filling on one side.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1030.jpg&hash=5e3dbc9debd3ebc2e5f403c9963d33560d640c4e)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1032.jpg&hash=84db6dcfe01ffb0cc989deaeb507baa2831d4454)

And everything after prep. Decals scrapped and sanded off, bondo applied.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1044.jpg&hash=0cfd5f8c03f198ada8ce1806b50140b60e28991f)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1046.jpg&hash=c295a2b0f115d37d56e0dafc6b363b073efe57f7)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1047.jpg&hash=05e6f12bad5e7687dfbc604aae34519da27d31c2)

Here is a rough sample of the color.  It's similar to the suzuki blue, with a lot of metallic though.  I was thinking about adding a purple ghost pearl, but I'm not sure I want to go there.  Has the potential to be awesome, or just fruity.  What do you think?
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1027.jpg&hash=216a491a4e3dee315771cbc7886023195bd8b96f)

And there you have it!  The goal is to get her running like a top before warm temps roll around here in Central Illinois.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: adidasguy on February 12, 2012, 11:09:52 PM
Some gravel and vinegar in the gas thank. That gets into more places than a chain.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: Kijona on February 12, 2012, 11:59:51 PM
Or stainless steel BB's from walmart. :)
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: Kijona on February 13, 2012, 12:05:06 AM
I STRONGLY recommend you read this before putting vinegar in your gas tank: http://gstwins.com/gsboard/index.php?topic=58650.msg667975#msg667975

Not to dissuade you, though! It's a cheap and incredibly simple way to get all that SHIZAM out of your gas tank.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on February 13, 2012, 07:57:49 AM
Planning on doing a POR-15 treatment.  First I want to get as much of that old coating out as possible.  I will have to try some gravel or bb's or something smaller like that.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: mankyle on February 13, 2012, 02:17:17 PM
I haven't tried it yet but my plan of action for my tank (also has old coating that is falling off) is to use the "heavy duty" POR-15 kit with the Tank Strip that is supposed to remove the "old inferior coating".  http://www.por15.com/HD-CYCLE-TANK-REPAIR-KIT/productinfo/HDCTRK/ (http://www.por15.com/HD-CYCLE-TANK-REPAIR-KIT/productinfo/HDCTRK/).  Its only 6 bucks more and should save you the hassle.

There was a guy on here that did POR-15 tank coatings, maybe he can chime in as to how well the Tank Strip int he POR-15 kit works.

Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on February 13, 2012, 02:49:33 PM
Awesome.  I will have to give that a try.  Ordering the HD Cycle Tank Repair Kit right now.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: Kijona on February 13, 2012, 04:03:03 PM
This is a quote from that thread that tells you how to remove crap from your gas tank. The guy even posted pictures if you want to see how well the steel BB and vinegar trick works. Please read more in the thread, though.

Quote from: Kijona on December 30, 2011, 10:06:26 PM
Quote from: vasama on December 29, 2011, 10:24:56 PM
Hello, all

Away from the computer the last couple of days...

Please, I didn't mean like I wanted advice only from Buddah... Not at all! the only reason I asked him directly is because it seems like he has lots of experience with carbs, from reading some of his posts, and I was curious on his take. I apologize. I truly apreciate everyone's comments and suggestions.

I did put the carbs bodies in boiling water for about 10 minutes. A ring of grime was formed at water level on the pot I used. The carbs didn't come out squeakly clean, though. The outside was still a bit dirty, and some dark areas remained on the inside. I want to boil them again. Should it be longer? I'll also try the pinesol... For how long?

The bike has 11k miles on it.

As for a leak on the boots, I did a WD40 "leak test". No change in revs after spraying it all around the boots. I believe (and hope) that it'll be down to thorough cleaning, and perhaps valve adjustment. I'll be doing the steel bb's (what about pellets?) in vinegar tomorrow for the gas tank. I'll be cleaning the tank petcock with compressed air. The bike was rejetted about two months ago, following the recommendations in this site. The exhaust is stock. When I rejetted, I also changed the valve needles and their seats.

One of my original questions: Can anyone confirm whether or not this carbs have the emmissions circuit or not? The bike is a 2002 (2001, really) but its carbs are not what the Clymer book show. They're more like the previous model year.

Thanks again

No problem. :) All in the name of helping a fellow rider!

I have no idea about emissions circuit but I can offer the following:
Steel BB's (I believe they're plated in nickel but you might luck up and find some stainless steel ones) are your best bet. They're ultra cheap at Wally World. I don't know if they make steel pellets but it seems unlikely. Plus, you get like 5lbs of BB's for the price of what you'd pay for one package of the pellets. Don't use the lead ones! Too soft. Also, DO NOT USE COPPER...obviously.

Step 1: Go to $1 Store and pick up two gallons of whatever vinegar they have (white is best because you can tell how dirty it gets, plus I think it's slightly stronger versus the others)
Step 2: Go to Walmart and pick up a big container of the silver BB's (I'd give you a link but I can't find them on wally world's site).
Step 3: Pour one gallon into the empty gas tank and slosh it around for about 5-10 minutes to ensure you get everything nice and saturated
Step 4: Let it sit over night (or 8hrs)
Step 5: Dump the whole container of BB's into the gas tank
Step 6: Start shaking/sloshing/whatever as long as you possibly can until you're tired.
Step 7: Take a break
Step 8: Repeat step 6. Be sure you turn it every which way and get those bb's really rolling in there.
Step 9: Drain that mucky mess out of there. Leave the BB's in for now.
Step 10: Add the second gallon of vinegar and repeat steps 6, 7, and 8.
Step 11: Drain everything. If it's still REALLY dirty at this point, you might want to rinse it a third time with the BB's. Note: will require more vinegar! :D You can re-use the BB's though. Just put them in a towel and clean them (use the "bowling ball polishing technique"...this will work nicely)
Step 12:  Add a gallon of your favorite, cheap gas and slosh it around AGAIN.
Step 13: Drain and give your lawn mower some "spiked" gas.  :laugh:

Hope this helps! :)

Edit: For step 10 you could probably use half a gallon.  :dunno_black: You decide!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on February 13, 2012, 04:23:02 PM
I might try the steel BB's along with the tank stripper that comes in the POR-15 HD kit if it's not working.  I don't know if vinegar would cut through the old tank coating.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: Erika on February 13, 2012, 09:14:43 PM
I've used evaporust in an old gas tank before, it neutalizes rust by binding to the iron in iron oxide and oxidation stops, and turns into something more stable. After I used an old chain and knocked out any loose stuff, I rinsed it well and then let the evaporust sit in the the tank for a day. It is non-toxic and won't hurt your paint job or your bare hands. After that, I dumped it into a bucket and kept the extra evaporust for bolts and other rusty parts. I rinsed and blew some air in the tank to dry it well, then filled it up with gas immediately to prevent flash rust. I was going to have the tank coated, but never did. I think I'll just let it be because that flaking stuff looks like such a pain, and my thought was to check it and use more evaporust when needed... maybe at the end of a riding season. I haven't had to yet, but I'm careful about letting the tank sit for long without keeping it topped off with gas and stable.  You can use it repeatedly until it eventually loses its potency over time(A friend of mine calls it Jesus Juice)

http://www.evaporust.com/evaporust.html
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: willi777 on February 24, 2012, 05:33:23 PM
 You can try using electrolysis to remove the rust in the tank- i haven't tried it yet, but read about it on the Katriders board. It's supposed to work pretty well and doesn't cost much, just the price of some washing soda... the thread is here if you wanna check it out
http://katriders.com/vb/showthread.php?t=95247
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on February 24, 2012, 08:46:51 PM
I already have the POR-15 HD system in my possession.  I will post up some pics of the results when I use it.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: ninjeff on February 25, 2012, 02:00:16 PM
Looking good man.

I'll be sure to saunter over to your house when i inevitably break something on my bike.  ;)
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on February 25, 2012, 08:38:46 PM
Quote from: ninjeff on February 25, 2012, 02:00:16 PM
Looking good man.

I'll be sure to saunter over to your house when i inevitably break something on my bike.  ;)

Sure thing man.  As long as you don't mind wrenching with someone who has learned from trial and error, a manual, and this website.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 02, 2012, 04:21:22 PM
Alright guys.  After 3 hours of working on stripping the old coating off the inside of the tank, I don't think I'm that much closer to being done with it. Got some pictures for ya...

First I got that old chainsaw chain out, then I duct taped the bottom opening off and poured in the POR-strip stuff.  Slushed it around for 15 mins, and then opened it back up.  To my dismay, as I look into the tank while draining I see stacks of the old tank lining like wet leaves piled up in the bottom of the tank.  To make things worse, there were still lots of areas of the tank that still have the old coating on it, and it's flaking off just like before.  I stripped off plenty of the paint on the top of the tank and the bottom while draining, but I don't care because it's getting repainted anyway.

Here is the flakes piled up in the bottom of the tank.  At this point I'm thinking...no way am I going to get all these out.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1071.jpg&hash=e0d82df52b28f9a4332c989a4f66efbc80610248)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1072.jpg&hash=a43e5a26f029683bff209fafe0ad1919e2c839a9)

So...I had a bigger job than I hoped on my hands.  I figured the first step is to get as much of that old loose coating out as I could.  After rinsing the tank out with water a few times, I starting contorting, shaking, reaching in the tank with pliers, and my fingers.  Let's be honest, there was no way I was going to get it all out this way.  I finally figured out how to work smarter instead of harder.  I found some cardboard packing paper and ripped it into a long strip that was wider on one end.  I stuck the wider end down into the tank, and let it unfurl.  Now tipping the tank to one side and then the other, I could catch the flakes as they dropped and the paper would guide them out the filler hole.

(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1075.jpg&hash=27e83ba42ea3356bc1463197bee2d0b8d1f85593)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1076.jpg&hash=79c09d88e850aff4559c2d10bc7848a7dc748eb6)

I got 99% of the flakes out this way. 

Look at all that coating that came out, and it's still half in there!
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1077.jpg&hash=f16219b07fdd8737d1f9affc5ea45f8843f43c9d)

There was one chunk that came out that was huge.  It was as thick as my thumb and sponge like.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1078.jpg&hash=6ff6c8669ab14586a1c404c7518d5c6be6fcd7c3)

This is where I'm stuck at this point.  Still lots of coating in there that is flaking off.  Seems like the PO did a terrible job at applying the the previous coating, or this is just how these coatings like to die.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 03, 2012, 12:34:59 PM
I read some places about using acetone to eat off the old coating.  Another option someone mentioned was Methyl Ethyl Ketone 10% (MEK) and 90% Xylene.  These are apparently available at paint stores.  Anyone have experience with any of these?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 04, 2012, 02:06:44 PM
Attempting acetone with 2400 bb's this afternoon.  Appears to be doing some good, but it's not the magic bullet.  I will have to do another clean out.  After I rinse a few times I'm going to use a pressure washer in the filler cap to get at what I can.  I might take a run to Sherwin Williams to see if I can get some of that MEK and Xylene too.  More updates to follow...

EDIT: A few patches of the old coating still remain.  I'm going to hit it with another solvent and see if I can get it out.  Still have alot more flakes of the old coating to get out as well.  I'll do some testing to see which solvent actually attacks this stuff the best for the benefit of any others who run into this problem.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 04, 2012, 08:21:51 PM
One of my main problems in this process is that even if I could get a solvent that really eats this old coating, I couldn't keep it in place around the petcock hole long enough with just duct tape.  Does anyone have an old petcock valve that does NOT work (ripped filter etc.), but could be used to plug up the tank with the stripping agent?

EDIT: I think I might try a cheaper paint stripper again.  The POR-15 stuff is $20 bucks a quart by the time you get it shipped.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: vasama on March 05, 2012, 09:19:55 AM
Hi, there!

First, I have a bad petcock that you can use. PM me to give me your address. This is a good oportunity for me to give back and get some good karma after I was helped by adidasguy.

Second, I strongly, strongly, suggest that you bite the bullet and simply take your tank to a radiator repair shop that would de-rust and flush it. It should cost anywhere between 35-50 bucks, but they'll do the job in an afternoon and your tank will be good as new. In my opinion, anything else (acetone, vinegar, bb's, etc, etc) is just a big waste of time.

Mauricio
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 05, 2012, 09:30:22 AM
Thanks vasama!  PM sent.

As far as the radiator shop goes...I'm a bit too far in to do that now I believe.  If rust were the only issue, and I hadn't already bought the POR-15 kit, I might actually start looking for a shop that would do it.  Do you think a radiator shop would be able to get that old coating out completely?   That's really my problem at this point.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 06, 2012, 07:22:14 AM
I bought some xylene and some MEK.  $35 bucks later, I went home and poured a little into a bucket and plopped in a big flake of the old coating to test.  The xylene by itself did basically nothing.  Added the MEK and it maybe softened it up a bit, but nowhere near dissolving it.  I'm getting a bit fed up with this thing...I might as well try these solvents in the tank since I have them.  I'm going to wait until I get the old petcock from vasama and then seal the stuff in there for a long time for maximum effect.  If that doesn't work, then I might try a paint stripper again.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 07, 2012, 08:21:55 PM
Engine is back in the bike now.  Old chain is ground off.  Gotta get this tank done.  It's killing me not be able to ride.  It was 65 here today.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 09, 2012, 05:12:55 PM
Put carbs and muffler back on and attempted to fire her up with a bottle as a temporary tank.  Jumped it from my car (without the car running).  She would only run on the right hand cylinder.  I switched the plugs and still the same issue.  I didn't have time to get into it any more than that.  I got at least some spark with the left plug up against the frame.  Anyone want to help narrow it down for me?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 11, 2012, 08:43:01 AM
Well...here is the plan.  I don't have a compression tester, so I will have to save that test for later if I can't figure it out otherwise.  I already pulled the carb and adjusted the left side float height a bit.

1. Clean all electrical connections to make sure that I'm getting good current flow.
2. Switch coils from one side to the other
3. Electrical diagnostics tests.  Not sure what all is involved here, but I have the Haynes manual so I'm sure I can find some good tests there.
4. Clean out the carbs once again (did all new seals and jets last fall, and drained the fuel from the carbs during the winter, so I doubt this is the issue)

Any other suggestions?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 11, 2012, 12:52:30 PM
I cleaned some electrical connections and switched the coils.  At first, still the same result.  It was only running on the right hand cylinder.  I messed with the idle screw a bit, and it eventually started running on both cylinders.  I even got it to idle for a moment on just the left hand cylinder after it warmed up.  Revving slightly up to 5-6k and she came back down a pretty slowly to idle.  Could be because I didn't have the airbox on the bike...  Also, I might have a slight exhaust leak since I didn't replace the header gaskets when I put the exhaust back on.  Also, the choke seemed to have almost no effect on the rpms. 

<venting>
I'm so flipping paranoid with this thing.  I'm also worried about my valve job not being right after all the pulling the cams on and off.  I think of anything and everything that could go wrong, and I can't seem to attack things one by one.  I'm all over the place and frustrated.  Between the tank and carb and other issues...ugh.  It kills me every time I see a bike out riding.
</venting>
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: ninjeff on March 11, 2012, 03:08:23 PM
Quote from: bombsquad83 on March 11, 2012, 12:52:30 PM
I cleaned some electrical connections and switched the coils.  At first, still the same result.  It was only running on the right hand cylinder.  I messed with the idle screw a bit, and it eventually started running on both cylinders.  I even got it to idle for a moment on just the left hand cylinder after it warmed up.  Revving slightly up to 5-6k and she came back down a pretty slowly to idle.  Could be because I didn't have the airbox on the bike...  Also, I might have a slight exhaust leak since I didn't replace the header gaskets when I put the exhaust back on.  Also, the choke seemed to have almost no effect on the rpms. 

<venting>
I'm so flipping paranoid with this thing.  I'm also worried about my valve job not being right after all the pulling the cams on and off.  I think of anything and everything that could go wrong, and I can't seem to attack things one by one.  I'm all over the place and frustrated.  Between the tank and carb and other issues...ugh.  It kills me every time I see a bike out riding.
</venting>

Tell me about it man! It was freaking gorgeous here today, and i saw a number of bikes out. Hell, even in my parking lot there were 4 bikes out from winter storage. I even got a message on MY bike from another tenant asking if i would sell it!

I can't ride right now either cause of the carb issue and i havent registered it yet. So, instead i sat on it and made vroom vroom noises.  :cool:
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 13, 2012, 07:25:51 AM
The more I have thought about it, I think my issue could have been mostly due to old/bad gas.  I need to figure out whether the coil wire that pulled out of the coil is an issue as well before I get it completely ready.

In other news, my friend tried some kind of soy-based paint stripper that he uses in his woodworking business on a flake of that old coating that is hanging on in my tank.  He said after 4 hours the flake got very soft and started to fall apart.  This might be the ticket to get the tank cleaned out before the new coating.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 14, 2012, 08:47:02 PM
Progress!  I used this soy stripper that I got from my friend, and I've got it all stripped off the inside after letting it sit in there for a whole day (24+ hours).  Still have to get some big chucks and small flakes and a few random BBs to get out of the tank before moving on with the POR-15 process.  Pics to follow tomorrow.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: willi777 on March 14, 2012, 09:12:51 PM
 After seeing the junk on your petcock, i would suspect some of it got into the carbs and is blocking one of the jets. Might wanna take off the float bowls to see if there's any evidence of it there.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 15, 2012, 01:53:52 PM
Everything in the carb should be pretty clean.  I cleaned it up and replaced all the jets at the end of last year when I was trying to get the bike running better, and I drained the carbs completely for the last 3 months.  Only ran the bike with the gas tank on a couple times, and wasn't having the same issues then.  I will be giving them another once over if I still have the same issues with some new gas.

In another note, after doing some more research this old coating is definitely POR-15, just applied very poorly by a PO.  They left large pools of the stuff in the bottom of the tank in some areas instead of draining the excess, and from everything I've read you shouldn't have the non-adhesion and flaking issues with POR-15 coating unless you do something wrong in the process.  This stuff should be a "lifetime" coating.  No wonder it was harder then heck to get out!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bigbad1ton on March 15, 2012, 06:47:04 PM
Great progress. I hope to go through my bike after this season. Hit the left carb with some carb spray or starting fluid. If it starts hitting then you know if it's fuel or fire.

I have been fighting carb issues for awhile now. And after reading a thread here found I was missing the vacuum O-ring beside the diaphragm.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 16, 2012, 08:55:02 PM
Quote from: bigbad1ton on March 15, 2012, 06:47:04 PM
I have been fighting carb issues for awhile now. And after reading a thread here found I was missing the vacuum O-ring beside the diaphragm.

Yeah, that is a common problem, which I've already dealt with before.

I've made more progress with the tank.  The soy gel did great.  After rinsing it out with water several times and once with acetone for good measure, I loosened the last few big chunks of the old liner manually with a long steel stake.  To get them out of the tank I took advantage of their sponginess and stabbed them with a drywall knife and yanked them out with needle nose pliers.  Now there are just a few little sections of the old coating hiding out in the crevices and corners of the tank.  I'm not to worried about those.  If they haven't come out by now, the new coating should hold them in and seal around them.  Now some pictures!

Here is my homemade way to block the petcock hole.  Just a piece of wood cut to size and holes drilled in the proper spacing.  Then fold up some aluminum foil tape for a gasket.  Worked great!
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1103.jpg&hash=a2b02003855d8b6945141e2f9a332182961a563f)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1097.jpg&hash=8c63e597fb5362ef423b01872eee1092cf719e39)
Here's the tank after the soy gel was rinsed out.  Still has some big chunks to get out.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1102.jpg&hash=10ec3ab0903365ed3f683e06dde197069c649bb4)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1101.jpg&hash=a5dc57ac9a0adccee13556e85cc6b88ffa0325f0)
Had to do some tank some tank drying to get the last few flakes (and the remaining bb's that were hiding out stuck in the crevices) out with some more gymnastics.   A shopvac in a blowing configuration worked great.  I supposed you could use it in suck mode too?
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1119.jpg&hash=fd89536a241d020ae6fb3bae320e1590e72b1c04)
Here you can see the biggest chunks that I got out with the drywall knife stabbing method.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1117.jpg&hash=efaf433aeb3ed9b7f8ae79cbea71751055c3dbc7)
I even borrowed a cool flexible camera tool from a coworker to check those corners of the tank you will never see.  Yeah I know...I'm anal retentive.  There are still some old flakes of liner in the corners.  I'm over it at this point.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1124.jpg&hash=2779a13cefc13ef2b9d2f4685a7040f2e64146a4)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1122.jpg&hash=a192aec8f768c1ac1b66bcf9215972ed944fd29a)
Lovely rust ready to be treated and sealed off forever
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1118.jpg&hash=0595523d75ec05d55c244c3987a351be7d5f136f)

I boiled some water and mixed it in Marine Clean for the next step in the process.  It's diluted about 2 or 3:1.  I'm agitating and rotating the tank around every hour or so until bed time and let it sit overnight.  I put a light metal chain in there along with some random screws.  No more steel BBs!  Those things were kind of a pain to get out... Tomorrow one more rinse with the last of the Marine Clean, and on to the Metal Ready and the sealer!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: cbrfxr67 on March 17, 2012, 06:50:19 AM
Fzantastic job on pics!  (applause)  Bosch videoscope,..nicenessss!  I love my Visual Optics videoscope.  It's one of those things that is great to have when you need it.  Shopvac idea is a good tip too!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 17, 2012, 08:10:26 PM
Took apart the carbs and soak the bodies and the float bowls in carb cleaner for an hour or so.  Couldn't have hurt anything at least.  I also confirmed that the new needle valves that come with the K&L rebuild kit are indeed shorter than the ones that were in my bike when I got it.  Not only that, but the valve seat is also slightly different.  The new needle and seat would not close properly even with extreme adjustment to the float height.  When check the float height with external gas line to the carb drain, the gas level would be much higher than it should be.  I ended up using the new seat with the old valve needle.  I was able to get the gas level correct on one carb, and just slightly above the gasket on the other.  Seems like whatever i do with the tabs/float height, it doesn't seem to have the proper effect on the actual gas level.  If this set up doesn't work out, I'm going to order new OEM needle valves and seats.

I also started the acid step on the gas tank.  Going to be turning the tank and letting eat away the rust that is left, then hopefully sealing tomorrow!  More pics coming soon.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 18, 2012, 07:57:47 PM
Here are some pics of the carb cleaning process.

Dipping the carb in cleaner
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1127.jpg&hash=b88f1da67a97f13a65e28f790b075d2eb603121b)
What all the parts of a carb look like, other than the body of the carbs themselves
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1125.jpg&hash=50d49ac51ff83c560a5c28168ee54700585dac1a)

Back to the gas tank sealing process.  Here is picture of the tank still wet after the last metal ready acid step.  Still some rust in there...hoping it will be ok underneath the sealant.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1128.jpg&hash=0820047ced101186c7371177069bc1a6150c1a0e)

I had some trouble getting that stupid chain out.  It got wrapped and knotted around the water drain tube, and also one end got deeply stuck in a crevice of the tank.  I finally got it out, had to really yank on it.  Had to beat on the corners of the tank to get all the screws and remaining flakes of old liner out of the crevices. 

Here is a picture of my drying set-up.  Two C-Clamps and the shopvac.  Worked great, about 3 hours later the tank was definitely bone dry.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1130.jpg&hash=423ad0299d8f1301d3c4fe22ac374a465e213cad)
Dry tank
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1138.jpg&hash=68d048748a238996229a147c0f0f4608d6a3dacc)

Put in the sealant next.  Rolled it around to cover all the sides, then drained as much as I could.  I'm letting it cure up side down so that the thickest coating will be on the top (unlike what the PO had done before).  Cleaned out the threads on the bottom q-tips. I will have pics of the finished job later in the week. I think it's looking pretty good.

While I was waiting for the tank to dry, I had a couple other things to take care of.  I needed a spacer on the CRF250X petcock to put it in a more reachable position, and to lock it in place.  I made this spacer/adapter out of wood and a screw that a ground the tip and the threads off the end.  It matches the little nipple that comes out of the stock petcock to keep it in place on the mount.  I painted it black.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1131.jpg&hash=e662b6e4ac8784d5f6214060aae4d6286b8150b4)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1132.jpg&hash=7be3b2caaeda674c1f12203c50f9cdd74d586fa3)
I had to use a longer bolt, but it mounted up really nice and tight.  Now the petcock doesn't move around when you try to use it, and it's in a great reachable position.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1133.jpg&hash=ca3301e33c5c7bcd3e93958309d2d5ca791ca3c8)
Fuel lines still run nicely behind the frame.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1134.jpg&hash=4ec04c1517ea363efdffb12273c8b05a3a92ee9f)

I also sanded down my old rusted, battery acid corroded battery box.  Then I treated the rust with some CLR and rinsed it and hit it with some acetone and alcohol.  Then I sprayed it with some flat black rattle can I had laying around.  Came out alright.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1135.jpg&hash=e21321b7e2fe249364facecd52b678dab046fa8b)


Title: Re: Bombsquad's 1993 GS500e refresh
Post by: cbrfxr67 on March 19, 2012, 07:01:51 AM
This is going great.  Really liking your thread sir!  Applause for pics!  I got a 900rr tank that I'm going to have to do something like this to.  Another way I like to dry out my tank is put my heat gun on low and set it up to blow right into the opening.  And 'why not' use a piece of wood?  Makes sense,....hmmm
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 19, 2012, 07:19:22 AM
Thanks CBR.  I would use a welder and drill press if it had access to them at home, but hey, why not wood?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 19, 2012, 09:08:10 PM
Installed my battery box and routed the wiring harness.  Used some nice thick weather strip to pad the battery box.  Gave both ends of each connector a squirt of WD40 (I assume this would help get a better connection?).  I also realized that my neural light is apparently burnt out all of a sudden.  Add another part to order to the list...
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 20, 2012, 07:30:20 PM
Looked into the tank tonight with the videoscope.  Here are the pictures.  I think it came out ok, but you experienced POR guys tell me if this looks ok or if something is wrong.  I think it looks ok on the bottom, but the sides and top are not completely silver and have some texture to them.  Please give feedback if you feel necessary.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1148.jpg&hash=e93c18e7f583ffaa18336296cd8eb2cc777426db)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1143.jpg&hash=936493f46e9338c164f5ef48b8052ef3be34e2ac)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1145.jpg&hash=20f69a17e8ebdb6481a615823ac45fdccbb4d364)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1144.jpg&hash=961bf22441f0a5119814fc32b4dbf62fb2ddc319)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1147.jpg&hash=4a60056e37d3ec7a73b4cece382fc20360de58c7)

Alright guys, done with the tank (hopefully) and moving on.  Got some other things done tonight.

Replaced my burnt out neutral light.  Lucky that I had a bulb laying around that was a similar size.

Bought 12 new stainless steel socket cap head bolts for the carb.  Replaced all those horrible JIS bolts.  Just a dab of blue threadlock on each of the bolts that went in the brackets holding the 2 carbs together.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1150.jpg&hash=9ee95a9ceadd104ce0597e0c9468c94270f24f69)

I mentioned that I routing the wiring harness on the left side of the bike.  I'm not sure that it's correct...  Take a look at this picture and please let me know how this is supposed to be routed. Nevermind, I found some good pics that BaltimoreGS posted.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1139.jpg&hash=09a4873b7fe50211fff6441473814ecef6fec178)

I put the carbs back on and the airbox and fired her up.  Now...here is the issue.  It was only running on the right hand cylinder again to start!  Once it warmed up, or if I revved the engine, the other cylinder would kick in.  At first it needed the choke just to run, then after it warmed up the choke didn't seem to do much.  In fact, it seemed to kill it a little.   So, what do you guys think?  I have already switched the plugs and the coils independently to no effect, so that is out.  Here are some possibilities I'd throw out and please add or subtract from the list if you can help.

1. Need to sync the carbs
2. Air mixture screws (3 turns right now)
3. Planning on replacing exhaust header gaskets (not sure they are bad, just old and the header has been on and off)
4. Float Heights.  I have been having trouble with getting the fuel level right no matter what I seem to do with the tabs.  I think I might have to bite the bullet and order OEM float valve sets.  I know it's right on the right carb, but might be just a bit high (1/8" higher than the gasket) on the left.
5. Electrical issue other than plugs or coils
6. Almost forgot compression test.  Can I borrow a tester from autozone or something?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 23, 2012, 03:23:50 PM
Synced the carbs...didn't help at all.  I also checked the float heights using a tube on the drain method.  They were both fine. 

EDIT: Here are some picks of the carb syncing device made from aquarium stuff just like the $5 dollar plan from the wiki. It was really $12.  Call it inflation.

(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1160.jpg&hash=bab81405baf4800038a730437035c3246087e729)
Had to stretch the tubing a bit with some needle nose to fit them on to the carbs
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1161.jpg&hash=8fc1b3a8f350966afb60fbeb472e66b79a4e47d2)
This the gang valve (actually a dual gang valve, but I'm only using 1 valve), along with the 2 T connections.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1162.jpg&hash=a43e7aeb046c235eb620bfe0c34da3fbf452ce71)
The water in the tubing on both sides.  Basically just get these level with the engine warm and idling at around 1750 by adjusting the carb sync screw on the throttle linkage.  Started with the gang valve open for coarse adjustment, and then closed it down slowly for finer adjustment.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2FIMG_1163.jpg&hash=65956a3fad97dd6f6baece7292e93c7af8ac07b8)


I think something bad is going on with that left cylinder.  I borrowed a compression tester from autozone, but it didn't have the right adapter for the threads (too big).  I did a quick thumb compression test on the left and I couldn't hold my thumb over the hole, so I assume there is at least some compression there. 

I realized that once it is warmed up, the left cylinder will only run when the choke is OFF.  This is why when I turn the choke on the rpms don't change that much.  It goes down to running on one.  I also messed with the mixture screw on the left all the way up and down and nothing seemed to help. 

1. Need to sync the carbs - This is out
2. Air mixture screws (3 turns right now) - Didn't improve
3. Planning on replacing exhaust header gaskets (not sure they are bad, just old and the header has been on and off) - Don't feel any obvious air leak, and I don't think this would cause the issue I'm having.
4. Float Heights.  I have been having trouble with getting the fuel level right no matter what I seem to do with the tabs.  I think I might have to bite the bullet and order OEM float valve sets.  I know it's right on the right carb, but might be just a bit high (1/8" higher than the gasket) on the left.   I checked these, they were actually fine on both sides.
5. Electrical issue other than plugs or coils - Could be?
6. Almost forgot compression test.  Can I borrow a tester from autozone or something? - Still need to get the right adapter

What do you guys think?  I need some help here!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 25, 2012, 07:28:53 PM
Tried to borrow a compression tester from autozone, but they don't lend a kit with the right size threads.  So, I ended up having to buy a kit.  Haven't had time to use it yet since the wife has me busy with house projects getting ready for junior.  I will get to it tomorrow.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: cbrfxr67 on March 26, 2012, 09:20:48 AM
then what happened??  need update!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 26, 2012, 09:48:32 AM
Quote from: cbrfxr67 on March 26, 2012, 09:20:48 AM
then what happened??  need update!

Hey!  Someone's watching... Will do the compression test after work today.  If that comes back ok, then I will be doing electrical system tests.  Any other suggestions are welcome!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: knowles on March 26, 2012, 12:08:00 PM
I look at yours whenever there is a new post. I pulling for ya man.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: cbrfxr67 on March 26, 2012, 12:16:35 PM
You'll get it Bomb!  I really don't think it is compression.  I can only say what I'd do.  I'd prob check carb diaphrams (vacuum good?), or coils first(had this happen on pesky F2 not firing on all cylinders and coil swap fixed that issue).  Just going over the basics will get you on track sir.
Such a pita though when you put so much time in and then find one header isn't even hot.  Ugh. 
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: steezin_and_wheezin on March 26, 2012, 12:31:59 PM
i love seeing everyone's project build threads. you definitely have more than 1 watcher :thumb:

Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 26, 2012, 12:48:16 PM
Quote from: cbrfxr67 on March 26, 2012, 12:16:35 PM
You'll get it Bomb!  I really don't think it is compression.  I can only say what I'd do.  I'd prob check carb diaphrams (vacuum good?), or coils first(had this happen on pesky F2 not firing on all cylinders and coil swap fixed that issue).  Just going over the basics will get you on track sir.
Such a pita though when you put so much time in and then find one header isn't even hot.  Ugh.

Really appreciate the encouragement guys.  I really like hashing things out with people throwing things out there.  Especially in this case when this is my first bike and I'm learning how to do this stuff. 

The carb diaphragms look ok, but it's not a bad idea to swap them and see what happens.  I already switched the coils and the plugs independently to no effect.  Thanks guys, and keep them coming!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 26, 2012, 08:07:36 PM
Now I'm thoroughly confused.

Started by rechecking my checking the torque on the camshaft bolts after calibrating my torque wrench (I won't get into this process now).  I also rechecked the timing.  Everything looked good and I put the valve cover back on and torqued it down. 

Now on to the compression test.  First I decided to do one cold test.

Left cylinder = 140 psi
Right cylinder = 140 psi

Now I'm thinking.  Great!  I probably won't have to rebuild.   So, I switched the carb diaphragms from one to the other and fired it up.  After realizing I need some longer fuel lines with my new petcock because the lines tend to pinch, it fired right up.  After just 10 seconds or so it shot up to 4000 rpm with the choke on.  I'm excited at this point because I know that's what it's supposed to do.  I take the choke off and it settles into idle at 1200.  Then the wierdness started again.  With throttle input it would backfire through the carbs a bit inconsistently, and then catch and rev great.  At this point I'm thinking this is all consistent with leaky diaphragms.   I shut it down.

Then I decide I might as well do a warm compression test.  Now this is where the real confusion sets in.

Left Cylinder = 110 psi
Right Cylinder = 120 psi

WTH!!  Shouldn't the compression go up once it's warm?

What's going on guys?  I haven't tried a little oil in the cylinder yet, so I guess that's the next step?  Maybe it wasn't all the way up to operating temp yet?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on March 27, 2012, 09:00:36 AM
All I can think about today is those warm compression numbers, and now I'm doubting myself as to whether I remembered to hold the throttle open.  Will test again tonight.

I ordered a couple new diaphragms on ebay as well.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 01, 2012, 01:53:37 PM
Got an update for everyone, and here is the good news.  I got to ride it today!  New diaphragms made throttle response much more consistent and got rid of backfiring through the carbs.  Redid compression numbers while she was nice and warmed up with the throttle wide open and got 135 in both cylinders.  Not great numbers, but acceptable for me I believe.  No difference points to another source for my left cylinder issues.  I also installed new exhaust gaskets.  I adjusted my throttle cable when I noticed that it would pull the throttle slightly when I locked the bars to the right. 

Still got some issues to work out though. 

1. Left cylinder still does not want to run when it's on choke.  It does sometimes when the bike is warmed up, but not consistently.
2. After riding her for a while. I started to notice a knock or a tick.  Most noticeable on deceleration.  I think it's in the valve train, but I'm not 100%.

I have video for both of these issues.  Will post them shortly.

Title: Re: Bombsquad's 1993 GS500e refresh
Post by: cbrfxr67 on April 01, 2012, 02:23:32 PM
At least you got to ride it a bit!  Definitely watching your progess!
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi682.photobucket.com%2Falbums%2Fvv188%2FTattooTaffy%2Fpopcorn.gif&hash=6f49a5d795cd80a0ce4cc2a228b99cb0c2356245)
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 01, 2012, 02:26:58 PM
In this video you might here some of the knock.  You also see how it acts when I pull the choke.  At first, it starts to rev higher as you would expect from a warm engine with choke on, but then goes back down.
http://s265.photobucket.com/albums/ii224/dtilford/GS500/?action=view&current=IMG_1180.mp4

In this video you can hear the knock/tick...I think it's coming from the right side of the valve train.
http://s265.photobucket.com/albums/ii224/dtilford/GS500/?action=view&current=IMG_1182.mp4
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 01, 2012, 07:15:15 PM
Rode it again this evening and didn't notice the knock.  I think it might be just the infamous intermittent camshaft knock that happens with pre-2000 (don't remember when they addressed it with different cam parts).  I'm not going to worry about it unless someone sees the video and warns me otherwise or it gets worse.

So that just leaves this annoying LH cylinder choke issue and paint left and she is done.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: ninjeff on April 02, 2012, 08:58:11 PM
what are your plans for paint?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 02, 2012, 09:09:09 PM
I bought automotive grade high build primer and auto grade clear.  A buddy of mine has a good paint gun and a paint room for his woodworking business.  He also has left over electric blue metallic paint.  A sample of it can be seen in my first post.  He said it will look a bit darker once it's clear coated.

I'll link to the products if it turns out well.

Heres a pic of the bike right now in my handlebar thread.  It's more naked then naked right now.

http://gstwins.com/gsboard/index.php?topic=59572.msg687866#msg687866
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 03, 2012, 06:52:07 AM
Here's the links to what I bought for paint, minus the base color which my friend has.  Bought it all through Amazon from TCP Global Corp.

Clear - http://www.amazon.com/gp/product/B004SQUCCS/ref=oh_o03_s00_i02_details
Primer - http://www.amazon.com/gp/product/B004SQTK9E/ref=oh_o03_s00_i03_details
Hardener (2 of these) - http://www.amazon.com/gp/product/B004SQU1X8/ref=oh_o03_s00_i01_details

EDIT: Asked my friend what he thought the base was.  He said it's Starfire brand urethane base, and it's Blue Metallic.  Here's the sample:
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Fstarfire_urethane_base_blue_metallic.jpg&hash=afe8feb9dcd3a9451fa470749bfc653ba93817b8)

Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 08, 2012, 08:49:39 PM
Ordered a new set of Pirelli Sport Demons today.  I also have 2 sets of parts carbs coming from steezin this week, so I'll be trying to figure out why my left carb is running rich.  Still have to get the paint done, and figure out whether the ticking/knocking in the engine once it gets warm is worth looking into any further. 

Any input on the paint color, tick noise (video above), carb issue, or how to mount tires myself is appreciated!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: ninjeff on April 08, 2012, 08:53:21 PM
I think the blue looks good. Classy.

If i may ask, how much did you pay for the tires? What size?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: hawaiianGS on April 08, 2012, 09:01:18 PM
Great to hear it's coming together for you Bomb. Love seeing the progress.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 09, 2012, 04:51:02 AM
Item   Status   Price   Quantity   Total Item Price
Sport Demon Sport Touring Front Tire
Color- --, Size- 110/70H-17
SKU#54891   Approved   $102.99   1   $102.99
Sport Demon Sport Touring Rear Tire
Color- --, Size- 130/70H-17
SKU#54899   Approved   $115.99   1   $115.99
Assorted Tire Iron Set
Color- --, Size- 3-Pack
SKU#40970   Approved   $22.99   1   $22.99
Valve Core Remover
Color- --, Size- --
SKU#41081   Approved   $2.99   1   $2.99

Grand Total:
$244.96


That is my order from motorcycle superstore.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: Manaenrc on April 09, 2012, 06:29:02 AM
What was the name of the soy based stripper that you used? The PO of my bike did exactly what you had with por15 flaking off. So I either need to take on the stripping project or look for another tank. Whatever direction I go I already have the new por15 kit to seal the final product. nice project btw glad you got most of your issues worked out.

Sent using tapatalk from somewhere in an andriod world
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 09, 2012, 08:13:06 AM
Stripping out that old lining was a huge PITA.  Honestly, I would probably recommend getting another tank that hasn't been lined before and doesn't have any pinholes corroded through it, then line it with your POR-15 kit.

I think this is the stuff, and I'll verify it when I get home if the label is still on the container.  It's not cheap.

http://www.amazon.com/SoyGel-Urethane-Remover-Stripper-Gallon/dp/B0002Z11MO/ref=sr_1_1?ie=UTF8&qid=1333984020&sr=8-1

I got it for free from a friend who does woodworking for a living.   There was only about a quart left in the container when I got it.  Keep in mind I had already hit the old liner with the POR stripper, and acetone before I used the soy stuff.  I think it would have worked on it's own though if I had a whole gallon of the stuff.  Acetone, MEK, Xylene and other solvents are almost useless against that old liner.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: Manaenrc on April 09, 2012, 08:32:31 AM
Yeah after reading through your experience with your tank I think I am going to take your advice and use the tank the way it is until I can find a replacement. The PO even JB welded the upper petcock to the tank. I don't mind when people use their head and do things in a different way, heck I'm all for thinking outside the box. But I just cannot take things that are not done properly to save time.

Thanks for your help and great thread BTW you did an outstanding job on the tank. Something you can look forward to using for years to come.

Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 09, 2012, 08:40:14 AM
Quote from: Manaenrc on April 09, 2012, 08:32:31 AM
Yeah after reading through your experience with your tank I think I am going to take your advice and use the tank the way it is until I can find a replacement. The PO even JB welded the upper petcock to the tank. I don't mind when people use their head and do things in a different way, heck I'm all for thinking outside the box. But I just cannot take things that are not done properly to save time.

Thanks for your help and great thread BTW you did an outstanding job on the tank. Something you can look forward to using for years to come.

Thanks for the compliment.  I'm hoping the paint turns out good on the tank and the lining holds  up better than the previous one did. 

JB welded the petcock to the tank....ouch.  New tank sounds like a wise decision.  Plenty of them come up for sale here.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 11, 2012, 04:56:07 PM
Slightly off topic, but I was taking apart the carbs that I got from steezin last night.  I thought my carbs were dirty...I hadn't seen anything yet.  (keep in mind I got 2 sets of carbs for relatively cheap, so it's perfectly ok).  One of the diaphragm cover screws was so seized up that I had to drill it all the way through and use an ez-out.  Unfortunately, it cracked the carb body on the outside when it came out.  I nicked the choke circuit with the drill too.  It's not leaking, but carb spray won't go through it like the other side.  Might have been clogged with something already.

Pics...
Broken off end of the screw on the ez-out bit
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F9eb388c0.jpg&hash=acbaf2d7929e320382dbbb40fadaa4e2b10d1a9d)

Crack and nicked choke circuit
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Ff8a5bea3.jpg&hash=5f43e92e13c8489a8f136c11a6b68e8c8991da32)

We'll see what I can do with these extra carbs, if anything other than part them out to people who can use some parts.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 14, 2012, 04:11:08 PM
Question for everyone.

I put on my new tires and put everything back together.  I noticed that the front brake drags a bit when I try to spin the front wheel after putting it back on.  Is this normal?

Also, the adjustment on the right side of my swing arm doesnt want to move to where it needs to be to be even with the other side.  I get my chain to where it should be in tightness,  but the right side just doesn't want to move to the same mark as the left. What's up with that?  It wasnt a problem before I changed the tire, but obviously the tire isn't the problem.  Is it my brakes holding the alignment out of place or could it be something else?

Pics of tire mounted to come later.

As promised...

I used a big woodworking clamp to break the beads on the old tires and it worked pretty well.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Ff8ead870.jpg&hash=d1cfd28fb61fdd8f34017777b7e0272f5f0d1b6b)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F38d15505.jpg&hash=62e9ff419da1444bd698ac8fbf3fc09d8dd771b7)

I cut the sides out of a used 5 quart oil jug.  They worked great to protect my rims.  I did very little damage to the paint, only one or two chips when my iron slipped off the plastic.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Fdb54755d.jpg&hash=4ddd66b0bb95be1d74666d746af26b99c1d104ac)

Title: Re: Bombsquad's 1993 GS500e refresh
Post by: knowles on April 14, 2012, 10:23:15 PM
I just bring them in to have them mounted and balanced, found a guy that does it for $16 a tire. good to see you making progress.  :thumb:
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 15, 2012, 05:50:01 AM
Took me 2 hours and it was my first time.  Paying yourself $16 per hour isn't bad.  I haven't found anyone around here that will do it for that anyway.  Thanks for the compliment.  Progress is relatively slow, but it's moving.  Hard to find time with all the house projects I'm involved in right now getting ready for the baby.

Anyone have any thoughts on my questions?

edit:
I did some forum searching, I think the dragging front brake is probably ok.  I think I will loosen the caliper on the rear in case it is preventing me from getting the alignment in the swingarm to move.  Then I will try to get it to move into place and align the rear wheel.  Then I will put the caliper back as the last step.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: dropitlow88 on April 15, 2012, 11:56:39 AM
Dragging front brake is A ok.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on April 15, 2012, 01:19:25 PM
Took the rear brake off and the wheel aligned just fine.  Took about a 30 mile ride today, other than it being massively windy, it was a great ride.  These new tires are awesome.  They are so much stickier and confidence inspiring in the curves.  :thumb:
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on May 05, 2012, 02:51:56 PM
Flushed out my brakes last weekend and I finally figured out why my bike didn't run right on the choke today.  The jet that is in the float itself that provides gas to the choke circuit was clogged on the cylinder that always cut out when I put on the choke.  I cleaned it out with a guitar string and it fixed that issue. 

Tried again to fix the gas level issue in my float bowls.  Cleaned my old needle valve seats and replaced the new ones that came with the kit.  Several tries at adjusting the float height yielded decent results.  I will be checking my plugs for richness periodically until I'm happy with it.  I also resynched the carbs. Seems to be running great now!  Can't wait to paint it.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: knowles on May 06, 2012, 01:03:36 AM
Quote from: Manaenrc on April 09, 2012, 08:32:31 AM
Yeah after reading through your experience with your tank I think I am going to take your advice and use the tank the way it is until I can find a replacement. The PO even JB welded the upper petcock to the tank. I don't mind when people use their head and do things in a different way, heck I'm all for thinking outside the box. But I just cannot take things that are not done properly to save time.

Thanks for your help and great thread BTW you did an outstanding job on the tank. Something you can look forward to using for years to come.

I still have mine to get ride of. $85 shipped in USA.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on May 06, 2012, 01:45:01 PM
After adjusting the float height and then riding for 80 miles yesterday, I took a look at the plugs this morning.  I think I've got her dialed in now.  :thumb:  Some of the black on the plug is from when the gas level was too high in the bowl.

Right cylinder
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F4df65035.jpg&hash=4a0c6457e0a2dc8955c313da4be55ef510be3f26)
Left cylinder
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F9259d93d.jpg&hash=5c28a39cbe47251240d75c440ff4ab395d9c5079)
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on May 17, 2012, 06:15:34 AM
Sigh...

After thinking I was done dealing with the needle valves for a while, I took the cap of my airbox drain this morning.  A full tube of gas drained out on my garage floor.  Soooo...looks like I will be springing for new OEM needle valves soon. 

I also noticed that one of my forks has a slight oil leak.  Just enough to make the tube wet and have a couple drops pooled on the dust seal and no more.  I just replaced the fork seals when I got the bike 500 miles ago!  I have been riding it around with no front fender....could this cause quicker seal death, or is my fork not capable of taking a seal and I need to replace the fork?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: Snake2715 on May 18, 2012, 07:11:20 PM
Wow man you have really made some progress.

Keep updating and the fork seal hopefully works out for you.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on May 18, 2012, 07:26:02 PM
Thanks man.  I have the new needle valves and a new fork seal on order right now from ronayers.com.   I'll get some more practice with replacing fork seals and hopefully the needle valves will be much better.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on May 22, 2012, 08:12:04 PM
The paint process has begun.  Will hopefully be done by early next week.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Ff20054f9.jpg&hash=be8b30dc60754ccc24931d1c03a5d632eb95d93a)

New fork seal on the way as well as new needle valves and some other random little parts like a new SUZUKI emblem for the engine cover, white decals for the tank, and molding for the bottom edge of the tank.

Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on May 29, 2012, 08:19:22 AM
Replaced my leaking fork seal this weekend.  I used the homemade tool intructions found here: http://beergarage.com/GSForkSeals.aspx .   It worked awesome.  I was planning on reusing my old fork oil until I spilled it all over my work bench and garage floor, so I need to get some more fork oil today before I put the front end back together.

I recently discovered that my front brake must have been dragging more than it should have been.  I noticed after a ride that the rotor was VERY hot, like too hot to touch even after 5 min of parking.  There was also a nice cloud of brake dust deposited on the inside of my right fork tube. Hopefully I can get the rotor aligned better when I put it back together this time.  Any tips for aligning the front wheel other than not tightening the fork brace screws until after everything else?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on May 31, 2012, 03:14:24 PM
Put on the base coat today.  Clear will go on early next week.

(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F006a56a9.jpg&hash=7d42b5aa018679c2a8fdf8a04b9a8e5e6eda2c00)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F51630d80.jpg&hash=8c294ab714f66ed471f05d1712caf02455051060)
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on June 08, 2012, 08:40:01 PM
All done with the paint now.  Buffed some of the clear that didn't lay out quite right the first time.  Starting with rubbing compound and rotary buffer with wool pad, then moved on to finishing compound.  Applied decals and a pro-grip tank protector (after the photos so that's why you don't see it.  Anyway...time for pictures!

Parts coming home.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Ff9fefdcb.jpg&hash=687a0fe6ef6a0b2c2c760cc9aca2c8a97d183dd2)
Last night before buffing and decals
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Fdaccbbb0.jpg&hash=d8655d0c3db3a299bc14b60f4c84c2c2c084184e)
Finished Product
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F66e06927.jpg&hash=50d76852310652af848fddfad843060436318013)
My buddy's DRZ-400SM in the background
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Ff3a20c60.jpg&hash=0a0604a7a9b2334a1821fe5ccb41d1d8bf1c2fc6)
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Fd9b8dd7b.jpg&hash=df56e37ef8fb5afb40a54cb001fc6275da7664b6)

She's not perfect.  I think I would do some more sanding of the primer coat to make sure I have a super smooth base.  I love the color.  It looks almost purple in some lights, and has a green tint due to the metallic in direct light.  It's a really brilliant blue.  Got a few tiny bubbles under the decal too, but they aren't too bad.

After adjusting the new needle valves (which I was able to do without tanking the carbs and tank our due to installing my socket head screws), I rode around most of the evening.  I noticed a new knocking noise in the front fork when it first compresses and then at the top of uncompression sometimes.  I think the spacer might be moving around a bit or something.  I'm not to worried about it because it handled great.  Didn't notice any leaks from the fork, but I didn't pay too much attention too it.  The brakes performed much better than they were after taking the front wheel of last time.  I think I got things better aligned this time so it's not rubbing too much.  My buddy said riding behind me he noticed a "burning smell" from the exhaust.  I think I've smelled it too after riding.  Smells a bit like metallic or rubber burning.  Hopefully it's normal.

Thanks to everyone for watching and for their help along the way.  I'm hoping this bike is going to be providing grins for me and my family for at least a few years to come!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: steezin_and_wheezin on June 19, 2012, 12:07:17 PM
Looks fantastic mang!! :bowdown:
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on June 19, 2012, 12:40:48 PM
Thanks man!

Two most recent photos of the bike...

One that was done for the picture game
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F87a47590.jpg&hash=32257dfdb99bedf370d0255d0cbf673573997795)

And I took a long ride to my parents house on Sunday and my dad took a shot of me on my bike
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2Fee24c5a9.jpg&hash=20a82d59122413d4f03d4ebbf51c455ef021f532)

I'm not worried about the smell I mentioned earlier, I think it's normal.  My decals layed out nice and flat now too. 

I am still getting the clunking noise in the front end, so I need to check that out.  Also, the idle rpms are acting somewhat lower than they were at first.  It's not bad at all, I think I might just need to tweak my mixture screws a bit. 

'busa rear pegs from ebay are on their way, along with reflective blue rim strips.

http://www.ebay.com/itm/380448082374?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649#ht_1104wt_1272

http://www.ebay.com/itm/260836170610?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649#ht_3362wt_1272

Title: Re: Bombsquad's 1993 GS500e refresh
Post by: 5thAve on June 19, 2012, 01:42:57 PM
Lovely rebuild! Good job on the bike and thanks for the good thread.

Brakes should only drag a tiny bit. Maybe time to buy some seals and rebuild the caliper? I've done it in two different bikes now. Not difficult at all. Just messy. I use a spray bottle from a dollar store as a vacuum pump to draw fresh fluid thru the lines as I refill and bleed the system. GS with a single caliper at each end is definitely a simple job to do.

Fork seals leaking is usually because of rust pitting on the cheap-ass chrome Suzuki used on our forks. If you have lots of rust, you're probably smart to think about new chrome uppers or any seals you put in will start leaking after a few hundred miles.

Sent from my T-Mobile G2 using Tapatalk 2
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on June 19, 2012, 01:49:07 PM
I was more careful about aligning the front wheel with my last installation, and tightening things down in the proper order.  The front brake doesn't drag much anymore.  Still enough to be pretty hot after a ride, but not super hot like before.

I will be checking my seals often for leaks.  If they start leaking again, it will be time for a new set of fork tubes.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: cbrfxr67 on June 19, 2012, 02:40:05 PM
Very nice!  Great job!  (applause!!)
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on July 05, 2012, 12:58:00 PM
Installed blue reflective rim strips.  Then a couple days later I realized that I put them further inside the rim than people normally do.  I feel like a bit of a dope, and I think I might have to get another set and put them on the outer part of the rim and remove these :(.
(https://gstwins.com/gsboard/proxy.php?request=http%3A%2F%2Fi265.photobucket.com%2Falbums%2Fii224%2Fdtilford%2FGS500%2F7c342e3e.jpg&hash=7e880de4952be6efd0eaead3d8164b28c5009976)

Also, the left fork is leaking very slightly again after a couple hundred miles, just as 5thAve predicted.  I think I'm going to leave it for the rest of this year unless it gets much more severe.  Then over the winter I'll have to find a new fork tube.

I also think I'll be investing in a new front brake system with stainless lines eventually if I keep this bike through next year.  I just want a bit more braking power and better feel.

I got these  (http://www.ebay.com/itm/260836170610?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649#ht_3342wt_1397)now, but haven't had time with the 100+ temps to get them installed and try them out.  I did get them ground down so they fit though.  Need to go buy some washers.  I'm curious how comfortable it will be with the shifter, since it's already a bit of a chore to get my foot over the top of the shifter to downshift since my legs are so long.  I made another post on this topic here: http://gstwins.com/gsboard/index.php?topic=61192.0

Also bought a K&N drop-in from jesterc on the boards here.  Plan to install it along with 127.5 jets sometime.  Might try it with my current 125 jets first.  I just saw on the matrix that someone else did 127.5.  Anyone have input on this?  I have a stock exhaust.

All of this could be a while before it gets done, considering my wife is getting induced on Monday with our first child.  :cheers:
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: BockinBboy on July 09, 2012, 09:49:29 AM
Congrats on the kid! Hope everything goes well today!  :cheers:

- Bboy
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on July 09, 2012, 04:00:57 PM
Holding my son in my arms now and he is perfect.  Thanks for the well wishes.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on July 20, 2012, 05:01:37 PM
Installed K&N drop-in today.  Also jetted up to 127.5.  Already have 40 pilots and 1 washer under the needles.  I think I might need to go up one size on the main and another washer under the needles.  That's just based on feel though.  I'll have to do a throttle chop and plug check sometime.  Right now it's definitely good enough to ride.  I also replaced my reserve fuel line that I had cut short to fix a leak.  Now I have plenty of extra line to work with.

Also got the eBay Hayabusa rear pegs ground down and installed in the front.  They do make my legs a bit more comfortable.  I didn't move the position of the shifter and it's not uncomfortable to shift.  I do have to be careful on upshifts to make sure I don't miss a gear.  I have hit neutral instead of 2nd a few times, and had a couple of momentary false neutrals on upper gears.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on August 13, 2012, 07:17:13 PM
Having trouble getting the jetting right with K&N drop-in.  I found 127.5 jets to be a little thin  on the throttle from 7k-9k rpm.  Definitely felt lean.  I upped to 130, and still felt a little lean, which was verified by the plugs.  132.5, and the top end leanness is beginning to feel better, but now it's feeling wet and rhythmic surging due to richness in the jet needle range.  I only have 1 washer under the needle, so I will remove it and see how it goes.  If it doesn't work completely, then I'm going back to my stock air filter with 125/1 washer.  It felt really good with that.

In other news.  After getting a seat needing a recover from steezin, I'm good to go for a cool project.  My father-in-law is a professional upholsterer, and told me about new type of padding that is a gel/foam hybrid.  It's called Gelee, and it's not cheap.  Will run me $90 at his cost for a slab of the stuff big enough to do the whole seat.  I'm having him make the seat padding a little wider on top and in the back, and a little higher for some more leg room.  It should be sweet when it's done.  He's covering it with AllSport 4-WAY Stretch Vinyl in High Tac (non-slip) black.   

Here's the link to the Gelee padding: http://www.duboisfabrics.com/product_p/foam-gelee.htm

And here is the vinyl: http://www.yourautotrim.com/alhbl.html
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: OrTahor on August 17, 2012, 03:25:46 PM
Great build! I am going to revive my 1993 GS this week. Following this thread!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on August 17, 2012, 06:09:03 PM
Thanks man, good luck with yours.  I've run into a snag that I hope turns out to be OK.  Read about it here (http://gstwins.com/gsboard/index.php?topic=61616.0).  I should have left well enough alone with the stock filter and jets!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on August 18, 2012, 07:07:15 PM
Back to the stock filter with 125/40/1 washer with the stock needle.  Runs perfect now!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: steezin_and_wheezin on August 20, 2012, 05:46:29 AM
Sucks you couldn't get it settle with the drop in k&n. I put one of those in the first gs i had(setup and jetting was all stock) it ran ok..

put any thought into going with the full lunchbox?
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on August 20, 2012, 06:09:57 AM
EDIT: The problem wasn't the filter itself, just that I didn't get the restrictor with it since I bought it from a board member that had already sold the restrictor.  With the restrictor I'm confident it would have been just fine.  I'm too OCD to just let it go and call it good enough, so I wanted to jet it perfectly for without the restrictor.  Decided it wasn't worth my time when I realized to be perfect I would probably need a different jet needle.

I've thought about it.  Putting performance mods into this bike just doesn't seem worth it.  I'd rather ride then spend all my time fiddling trying to make it run perfectly.  With a new kid and the little Honda project, no time/money for unnecessary mods to the GS.  To be honest I'm happy with the performance that I get from it with the stock air filter, and I have no plans to get a full exhaust.  For all the money I could put into performance mods on the GS500, I could sell it and add that to money for getting a bike that would go much faster.  :cheers:

The seat mod?  Now that is necessary ;).
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on October 12, 2012, 07:53:56 PM
Got my leaking fork replaced properly with a really nice upper tube from adidasguy.  He sold me a whole fork, but when I went to replace the seal on it the damper bolt would not come out.  I had to drill it out, so I swapped the nice upper into my old lower tube.

I had been filling to 99mm with 10w.  I realized that is too much oil with progressive springs due to the size of the spring vs. stock.  I filled to 130mm this time in with 15w instead of 10w.  Also polished both tubes a bit with 000 steel wool.  Hopefully it will be leak free for a good long while!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: Higgins13 on October 15, 2012, 07:13:10 AM
I think you need to find a home for these considering your name  ;)

http://www.ebay.com/itm/2x-Mario-Bob-Omb-1up-Funny-Bomb-Game-NES-JDM-Drift-Sticker-Decals-Any-Color-4-/271014210519
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on October 16, 2012, 06:43:22 AM
Stealing that thing for my avatar :).
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: ninjeff on February 27, 2013, 02:21:45 PM
Popped back on here to see how the bike was doing, and you really did make some great progress! Looks awesome dude!
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on February 27, 2013, 03:21:07 PM
Thank you.  I'm excited to get the custom seat back from my father in law sometime soon.  Also have an SV650 front caliper and very new '09 GS shock that I need to get on, and I need to change the oil.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: jacob92icu on February 27, 2013, 05:10:39 PM
Looking good! Wat color code did you use for the blue? And what color primer did you use? Just curious.
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: bombsquad83 on February 27, 2013, 06:01:06 PM
http://gstwins.com/gsboard/index.php?topic=59113.msg688017#msg688017
Title: Re: Bombsquad's 1993 GS500e refresh
Post by: pliskin on February 23, 2015, 08:34:22 PM
Damn, your tank ordeal is what I'm living right now. Only I'm doing it in sub zero temps. Did vinegar, BB's, coke which is same acid in prep n etch. My fingers are rust stained right now. I'm about to put fire to it the get the stuff out. Or I might leave the big chunks in and forget about it.

OK let's let this thread die again. It was good.