Author Topic: tobyd '98 GS  (Read 485 times)

Offline ajensen

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Re: tobyd '98 GS
« Reply #20 on: July 25, 2017, 08:00:07 PM »
Great information--keep it coming.

Offline tobyd

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Re: tobyd '98 GS
« Reply #21 on: July 28, 2017, 02:02:37 PM »
Hacksawed off the spacers for the front mount. Probably will replace these with thick aluminium washers and plain alu tube.



The bolt is rusted solid into the spacers although it seems all the corrosion is along one edge, I might cut one in half tomorrow to see how far the rust extends into the tubes as I might be able to gently pick out a lot of the rust with a tie wrap wire

Managed to sit the engine on one side to let the penetrating oil flow vertically so I'll take a look tomorrow and see if its loosened at all. Whole lot less to heat up though. Drilling it will be the sadness

Also noticed that all the available 2nd gs500e engines on eBay at the moment have either seized-in-place or broken-on-the-block front mounts. So looking to avoid that.

Engine needs a good clean so i'll look for some degreaser tomorrow and make it some sort of paddling pool to sit in and be de-skanked.

Offline tobyd

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Re: tobyd '98 GS
« Reply #22 on: July 30, 2017, 08:23:23 AM »
Drilled some of the engine mount but got tired and angry and rained on so gave up. I'll have a look in the week.

Framewise, its nearly stripped. Just the swing arm and suspension to go and all those nuts are loose. Whether the thing will come adrift I don't know. Times run out today for those.



Quite a lot of the bits thankfully come off as complete systems, the rear brakes from reservoir to caliper comes off in one contained unit. The front brake, once freed from its wiring comes off handlebar and all. the wiring loom mostly just comes off in one go.

Couldn't work out why the top of the yoke wouldn't come off, until I realised the steering lock was on...

I'll clean down the frame ones its ready for coating. Still don't know what colour I want. Thought about black but I don't think it will work, not sure about keeping it the same colour, its not the best silver (as silvers go) IMO.



something like this perhaps but not as shiny



or this, colour wise. that frame probably costs more than my house.


Offline tobyd

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Re: tobyd '98 GS
« Reply #23 on: August 05, 2017, 06:29:09 AM »
Frame stripped and somewhat degreased. Centerstand bolts had to be hacksawed off but was expecting that. Worst of the rot was at the centerstand but hopefully sandblasting will take care of that. I'll clean down what I can tomorrow. Going to the shop on Monday and I'll bring all the bits I'm tentatively interested in having done along and let the guy take a look. Would like to get the grab rails, heel plate mount triangle things and torque bar recoated in matt black so cleaned them down although the gear shift side heel plate is rounded off a bit... Will have to see what the powder coating place thinks and quotes on how many parts get done though. Might just get the matt black bits blasted and I'll 4" brush on bitumin.



Swing arm in not-awful shape under years of crud. The broken mudguard is jammed on though and I had to drill out the bolts for the chain guard.



'Slightly vague' rear suspension 'possibly' related to the knuckle 'bearings'.





yak. I don't know if the front one is so worn that its into the knuckle itself? They look pretty crusty too so not sure how to get those out for replacement anyway... We'll see. Might take the knuckle along to the sandblaster and get it cleaned up, not sure its worth coating or just replacing outright.

been ignoring the engine.

Offline ajensen

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Re: tobyd '98 GS
« Reply #24 on: August 05, 2017, 11:47:13 AM »
Y'all in the UK seem to have so much more problems with rust than we have in the US (I am from Florida and have lived in east Tennessee for the last 15 years). I wonder if it is because of so much rain, salt on the roads, if Brits ride no matter what the weather, or something else. By the way, my first bike was a brand-new BSA Bantam D1 (125cc plunger frame). Except for the plunger mechanism, I never had any rust issues--still have the Bantam although it now stays in my garage.

I am really enjoying your adventures with your GS and look forward to your postings.

Offline tobyd

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Re: tobyd '98 GS
« Reply #25 on: August 05, 2017, 02:11:09 PM »
I'm not so sure why its so rusted up. Its such a smattering in different places that's I guess its just not be taken care of for a long time. I don't recall the council making much effort to salt the roads but the bike's current registration plate is from a city by the sea so maybe its just sat on a seafront for 10 years and gone manky that way?

I don't understand how it got an MOT with a rotten exhaust and borked suspension. Perhaps the man-from-the-ministry was having an offday, or is easily bribed or was a moron. Who knows?

One day I'd like a Bantum, always liked how they looked and there is something appealing to me about an air-cooled 125 single from that era.

I really hope there is some positive progress to report on soon. Gotten a bit depressed cracking off bolts to find more rotted out fixings, the parts list is growing by the day and I've not even started on the engine yet :(

Offline ShowBizWolf

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Re: tobyd '98 GS
« Reply #26 on: August 05, 2017, 04:01:05 PM »
Don't let rust get ya down, Toby!! I am fighting that battle allllll the time here in PA. They put brine and other chemicals on the roads here in the winter time and it just eats away everything! Actually, IIRC, they had to stop in the last year or two because it was actually eating away the mounts for the plows on the trucks!

Here's my Turtle Van last summer when I was fixing the frame rails and fabbing up a new bumper bar (this is without the plastic bumper cover on). Rust sucks but it can be conquered!!!!
(I am just including 3 picture links because I don't want to clutter up your thread with my pictures)
http://i.imgur.com/AebzD4U.jpg
http://i.imgur.com/fFJj6Vk.jpg
http://i.imgur.com/rtBeuf6.jpg

You are not alone in your fight against rust :kiss3:
Superbike bars, 20w fork oil, '04 GSXR750 headlight w/LED H7, '01 GSXR1000 signals, Chuck81 fork brace, '05 Busa fender, stainless exhaust & brake lines, LED dash & brake bulbs, 140/80 rear hoop, F tail lens, fenderectomy, R6 shock, underglow, Bandit400 hugger, aluminum heel guards and pegs

Offline tobyd

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Re: tobyd '98 GS
« Reply #27 on: August 06, 2017, 11:05:38 AM »
Whoa, that's some rust going on there! I think its just the cumulative setbacks and the time wasted trying to save a few things that should just be tossed in the metals bin at the tip and replaced with a decent 2nd hand ebay special :angry: One day everything will be stainless steel and all fixings will be copper-greased. at least, I hope.

I've just spent some time with a steel brush wheel in the drill going over some things

That suspension knuckle is a write-off, no way is another bearing going to go into the remains of the hole. I'll try and get a breakers one, some guy is breaking a GS in town at the moment so waiting to hear back from him. Might be able to pick up a load of bolts and things and some other odds and ends to save buying new. Broken mudguard is off but I don't think I'll be putting a replacement in. I'm not even sure what it is protecting?

Ground off the other centerstand 'captive' nut, I think I'll replace those with nylocks or maybe just a single bolt through both mounts. Steel-wheeled some of the rest of it that was a bit crusty and I think the frame is by-and-large sound. Some bits aren't great but I don't think anything is more than superficial. Which I guess is the main thing.



The outrigger things for the passenger footpegs are a bit grim. And at some point someone has made a really poor job of rattle can silvering bits at random. I guess to hide some of the odd flaky bits.

Managed to free off the gear-shift-side heel guard so I'll see about getting both footpeg mounts coated in black. The seat-lock mechanism on grab rail doesn't seem to want to come loose, which is a bit of a sod since I wanted those cleaned up too. Might have to DIY them with hammerite and then a spray can. *update* Seat-lock saw sense so I'll take the grab rails along tomorrow.

Half toying with the idea of having the swing-arm in matt black too, and keeping the frame a silvery colour.
« Last Edit: August 06, 2017, 11:31:11 AM by tobyd »

Offline tobyd

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Re: tobyd '98 GS
« Reply #28 on: August 12, 2017, 02:35:00 PM »
Frame went to the paint shop on Monday, don't have a schedule so I assume it'll be sometime next week. Went for a black swing arm, grab rails, peg-mounts and center stand, and aluminium colour (so slightly darker than stock) frame. Should be getting a zinc coating pre-powder so it'll last forever or maybe longer. Or I'll crash it immediately and it'll be a pointless exercise in futility.

The old shock mount was a nasty piece of junk but found a local breaker had one for 30.



Except 35 buys you it and a gas shock (and 40 buys you the same plus 5 credit since neither of us had change). Looks like a circa 1990 unit in aluminium (I can well imagine the later 'its-made-of-rust' model appeared when someone noticed the insane amount this must have cost to produce) with pretty neat bearings. The gas shock from someone called bater or rator or something looks a bit iffy but I'll stick with it until an R6 upgrade, the original shock is a dog. I'll talk to the guy about a replacement instrument panel since mine is horrible and I need so many nuts and bolts now...

Cleaned the whole thing down and mashed loads of new grease into the bearings a few times and was generally quite happy with it.

The engine remains wrapped in a tarp on some blocks in the garden pending some decent cobalt drill bits (15 ones, they disappoint...) and cutting fluid to sort out the seized mounting.

Offline ajensen

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Re: tobyd '98 GS
« Reply #29 on: August 12, 2017, 10:26:11 PM »
Thanks for the update.