I hope this is redundant, but I just wanted to start a seperate thread for the rebuild project. I'll keep updating as I progress through the project and as you guys help me figure stuff out ;)...
The project bike is: 1991 Suzuki GS 500. I picked this bike up off of eBay for just over $200. I had to make a 2 or 3 hour road trip out to Philadelphia, PA to pick the bike up. Which was... interesting at best. Little did I know I would be diving head first into the slums of Flithadelphia to find this bike, let alone the crap I would have to go through just to find the guy's place. But alas, that's another story.
So, here are the pics, right after getting her into the basement.
(http://img.photobucket.com/albums/v357/BallerX/DSCF0989.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF0990.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF0992.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF0993.jpg)
Any and all input is welcome!!
I hope double posting isn't too terible of a sin...
Updates! I've starting the stripping down of the GS. And I've discovered the aft portion of the frame is bent... lucky me! I also used some carb cleaner to remove the Kmart spray bomb job on the frame to uncover the VIN number. Step one of the "lets see how hard PennDOT is going to screw me" experiment.
Anywho - latest pics:
(http://img.photobucket.com/albums/v357/BallerX/DSCF1021.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1018.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1019.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1022.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1023.jpg)
I'm going to be busy........ :cry:
Subframe damage....not too serious. There's a thread somewhere recently titled something like "does this look wrong?" that had a similar problem. He got it fixed without too much problem.
That poor bike has been abused. I'm glad it's in good hands.
Edit: http://gstwins.com/gsboard/index.php?topic=31022.0
That bike looks like hell on wheels. You gonna sand blast the frame? If I were you, I'd buy another parts bike that's been alittle less neglected. You can probably get one for $500 or less not running. You'd probably spend much more than that on parts in the long run. Are you looking to put it back in stock running condition or are you going to fab and upgragde? Looks like a fun project.
that looks like a good project, and a contender for a gsxr subframe (post srad. i found out the hard way the srad looks too fat on the gs)
$200 can't really go too wrong with that.
have fun :d
yeaa i'g go with a new gsx rear end :) looks fun ..been abused thats for sure but the fun thing about it ... you have it torn down .. i'd putl
some mtor work in to it :) send the heads off have it resleved or bored .. what ever it has .. build the up motor up why not you have it apart .. theres probly a shop around there that dose it for pretty cheep :) good luck keep us posted
Quote from: hmmmnz on October 20, 2006, 06:39:55 PM
that looks like a good project, and a contender for a gsxr subframe (post srad. i found out the hard way the srad looks too fat on the gs)
$200 can't really go too wrong with that.
have fun :d
Pardon my ignorance, but how do you go about getting the subframe off of another bike?
QuotePardon my ignorance, but how do you go about getting the subframe off of another bike?
many sportbikes have removable subframes, you can just unbolt them. I guess that you'd then have to weld some tabs onto your frame to bolt it on your bike. Most serious sportbikes are alluminum, so you can't just weld them on. I think it'd be kind of cool to just chop it off and leave just enough for the drivers seat. You couldn't carry a pasenger but it'd look cool and you'd have less bodywork to buy or make.
Any luck with spark or compression? Did you check? I hope it at least turns over.
Have fun! :cheers:
(http://i58.photobucket.com/albums/g257/hmmmnz/PICT0191Custom.jpg)
Quote from: Jarrett on October 20, 2006, 05:50:40 PM
You gonna sand blast the frame? If I were you, I'd buy another parts bike that's been alittle less neglected. You can probably get one for $500 or less not running. You'd probably spend much more than that on parts in the long run.
Yeah, I'm thinking sandblasting the frame is going to be the way to go. May go with a black finish instead of the silver - not certain though. Another parts bike had been a consideration of mine. I'm looking at this the stupid way - as a challenge to get this one running again. I've probably got about a grand in this project's budget...
Quote from: ducati_nolan on October 20, 2006, 09:13:15 PM
Any luck with spark or compression? Did you check? I hope it at least turns over.
Have fun! :cheers:
As far as spark - I have no idea. I do have decent compression and she turns over easy. I'm think of at least a top end rebuild on the engine anyway. Anyone know where I can get a bore kit??
Oh - and any suggestion on a dual headlight setup? I've seen a few of the rides around here with them, and that just looks sweet to me.
It's gonna be a long road - but I'm hoping to have it done by next season. (ha!) So wish me luck! :cheers:
Those are typically Buell Blast headlights. You have to make (buy?) some custom brackets for them to fit, but they look cool.
I can fab some brackets no problem, I just wasn't sure what make / model / etc. I needed to look for. Thanks for the info!
My dual headlights are from an 03' Buel Lightning. I got them at the local Buel/Harley dealer for like $65. they came w/ bulbs too :icon_mrgreen: The brackets are super easy.. I made mine out of alluminum and used the factory bolts and mounting point :thumb: If you need any pics PM me and Ill email em to ya
(http://i61.photobucket.com/albums/h55/scottpeel/DSC08558_sm.jpg)
I've got a few things off my 2004 if you're interested, that I'll part with cheap.
-stock handlebar (black) in perfect shape. $15?
-airbox & stock filter. roughly 2k miles on the filter. comes w/ everything to bolt it right back on. $30?
PM me if you're interested.
Thanks for the offer man, but the bars are actually in decent shape, and I don't want to swap them till i actually get a chance to ride the thing. And turdfergusson on this board is sending me a stock airbox already!
$65 from the Harley dealer you say?? That is such a sweet look. I do believe I'll have to go into the dreaded local harley dealer now...
Quote from: RiderX on October 22, 2006, 05:27:01 AM
I do believe I'll have to go into the dreaded local harley dealer now...
I'd personally wait a few months until it actually starts to look like a motorcycle again. :)
you should be able to get some quite cool street fighter style ones from online stores or ebay(http://www.busters-accessories.co.uk/prodimages/TWIN-HEADLIGHTS-CHROME.jpg)
http://cgi.ebay.com/ebaymotors/Motorcycle-Streetfighter-Headlight-Twin-Custom-SV650-SV_W0QQitemZ200037485808QQihZ010QQcategoryZ35598QQssPageNameZWDVWQQrdZ1QQcmdZViewItem
that seems a bit expensive, it might work out cheaper to get them from the uk and get them sent over
http://www.busters-accessories.co.uk/proddetail.asp?prod=THL
Yea, I think the headlights are the least of your problems right now ;) If I were you I'd get the frame cleaned up / straightened out and then start going through the wiring harness point by point with a multimeter. Once the electrical is sorted out then start looking at the engine.
QuoteYea, I think the headlights are the least of your problems right now Wink If I were you I'd get the frame cleaned up / straightened out and then start going through the wiring harness point by point with a multimeter. Once the electrical is sorted out then start looking at the engine.
Yeah, that's right. once the frame is done and you start putting everything back on, first try getting spark to the plugs. That's your main electrical priority. I'd also try to get the thing running and riding before you even do a top end. If the top end is shot it'll still probally run, it may smoke a lot but it should run well enough for you to make sure your bottom end and ignition are alright. You'd hate to do the top end and then find out that you have no oil pressure and a rod knock.
Headlights are the least of your worries at this point. But at $65 the buel ones seem pretty cool, but do that last.
Cool :cheers:
Well I wasn't saying I was heading out now... ;)
I dropped the enigne out this weekend - expect pics of that soon. I'm going to at least do a top end rebuild on the engine. As far as electrical - yes spark is a major concern right now. But I think I'll be able to achieve that much without too many problems. The wiring harness seems to be in suprisngly good shape.
So next I'm going to get the forks out of the way - but I'm wondering if I should bother with removing the swing arm or not...
I'm going to go to battle with the DMV next week, so that should be fun too.
:thumb: :thumb: if your going to mess with the front you might as well do the back .. you might look in to what its going to take to maybe do a 750 swap :) front and rear see if you can fit that in your budget .. check the local wreaking yards and ebay and see what you can find .. look on here to see what it might take to mod it to make it all work .. most of it sounds simple enough ...
Alright here are the updates - engine is out. I have the engine stripped down further than what is in the pics, and it doesn't look too good. I think I may need stock pistons and have the old cylinders inserts pressed out and new stock ones preseed in. That is of course - if thats possible - any ideas?
Or the alternative - any one know of a bore kit for a GS 500e?
Anyway - here's the pics, ugly as they are:
(http://img.photobucket.com/albums/v357/BallerX/DSCF1035.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1042.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1038.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1039.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1041.jpg)
Me needa lotsa da help!!
Find a running engine kit, with the carbs, the ecm, the wiring harness, All the stuff. and make a running motorcycle BEFORE you spend silly money on an engine build. Any mods on an un tested engine could be expensive and time consuming and unsucessful. Piecing the missing stuff is expensive. Find a kit.
Got one on ebay for the Horsey Project (91 GS500) For 175, picked it up in state next door. That was a great deal, and sometimes there are others! Good luck Rob
Oh believe me - I'm looking into all avenues. I'll start searching eBay for a kit. I may have a line on a lot of top end stuff, so we will see how that goes...
Awesome! You're making good progress! Keep us updated, I love project logs!
-Turd.
no doubt! keep us updated.
I am especially interested on your engine rebuild. I did a full rebuild/chop/restore on one of my GS's.
Here you can see my thread on that project. http://gstwins.com/gsboard/index.php?topic=24409.0
**this shows (sorta) the process I went through to remove the paint and rust for the frame. as well as my conversion from 95' fairings to 01' fairings.
it is my daily driver now.
Keep it up and post more pics. :thumb:
Dose the engine even turn over ir is it siezed? I doubt that you'll need to put new sleeves in the thing, a bore and the next size up pistons should be fine. You could even try running a hone through it to see if it cleans up without removing too much material, you may get lucky. That being said, you'd hate to spend your time and money on a top end and then find out that your bottom end is trashed, and with the ammount of rust and corrosion in your top end I wouldn't be suprised if the bottom end was corroded too.
A used engine would be cheaper than a full rebuild, but if you can get away with just a top end that would be cheaper. It's a gamble.
Have fun :cheers:
That poor GS... :cry:
I'm SO GLAD you're fixing it up.... Good luck with it! I can't wait to see how it turns out. :icon_mrgreen:
The engine turns over just fine. I'm just worried about investing money in the top end just to have the bottom end totally hosed. I've got several leads on used engines now. So I will keep you guys updated.
3imo - I love your finished product! Any pointers on stipping the frame/wheels?
I have a bare 89 frame ( no title - I got it for parts- sorry the engine is long gone..).
I'm getting ready to get rid of it (it's minus the removeable section..).... If you want it for replacing your subframe...it's here in Pasadena, MD. Just come get it...
It's in my way....
And if you decide to say the hell with the whole project -- I have a 92 and a 94 sitting here waiting for me to finish them up and put them out for sale...
The 92 has the famous....or infamous camshaft end play noise...
But Anyway.... if you need a subframe...
fyi...Suzuki does not make the +1mm pistons (75mm) anymore. I think they still make the +0.5mm pistons (74.5mm). Other options do exist for larger pistons like 78mm, but the total cost for parts/labor is around $350.
I do agree with D-N that the bottom end may (and probably does) have some corrosion as well. Pull the oil pan and see what resides there.
Since it turns over fine, I bet you could just hone it and replace the rings, reusing your pistons. Even if you take off a bit of material from the cylinders (porbally won't be much) you could get the next size up rings and file them down to the correct end gap. It should work just fine and it would be cheap, the only parts you need are the rings.
If you do decide to get the larger rings and file down the end gap, I'd recomend using the stock bore size oil ring.
Ne reason spending any more than you need to :cheers:
Quote from: dgyver on October 27, 2006, 01:00:13 PM.... but the total cost for parts/labor is around $350....
Hell - I've got an offer on a slightly used engine for less than that! I'm exploring engine and frame options right now. Should be coming to some sort of deal(s) by the end of next week. I'll keep you all posted.
I'm going to put the engine to the side for now - and focus on getting everything else off of my frame.
Some where on here there is a thread about building a larger displacemt engine you can use 79mm pistons from a 4 cylinder liter bike of some sort, cant remember where it's at but dig around if your going to bore the cylinderrs and have it apart anyway go big.
orrr you can go head get that new motor and get that poor gs back on the road... then save up some money and get that other motor moded out the end and just have one hell of a motor ready for one your other one gose out
Just some minor updates...
Nasty Pistons...
(http://img.photobucket.com/albums/v357/BallerX/DSCF1045.jpg)
I hope someone remembers how all this goes back in...
(http://img.photobucket.com/albums/v357/BallerX/DSCF1049.jpg)
Old nasty carbs...
(http://img.photobucket.com/albums/v357/BallerX/DSCF1050.jpg)
Pretty new(er) carbs! Much thanks to Jughead for these:
(http://img.photobucket.com/albums/v357/BallerX/DSCF1051.jpg)
I'm waiting for some more info from srinath(sp?) on a new(er) engine, and I think that should work out nicely...
That's boiled in vinegar? Amazing! Berryman's going out of business.....
:o Dang mine were Cleaner weren't They. Glad they Made it.That was super Fast for USPS.
Actually I didn't touch those Carbs at all.The Whole Bike is that Clean. :)
Quote from: Jared on October 27, 2006, 12:35:21 PM
I have a bare 89 frame ( no title - I got it for parts- sorry the engine is long gone..).
I'm getting ready to get rid of it (it's minus the removeable section..).... If you want it for replacing your subframe...it's here in Pasadena, MD. Just come get it...
It's in my way....
And if you decide to say the hell with the whole project -- I have a 92 and a 94 sitting here waiting for me to finish them up and put them out for sale...
The 92 has the famous....or infamous camshaft end play noise...
But Anyway.... if you need a subframe...
hey jared ne idea what youre goin to ask for one or the other? :thumb:
Mkay. I think I'm nearly out of things to tear apart. Man - I REALLY hope this thing goes back together with as few headaches as it cam apart... I know... pipe dreams...
Alright, heres the last of the dissasembly (i think):
(http://img.photobucket.com/albums/v357/BallerX/DSCF1062.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1061.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1059.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1058.jpg)
(http://img.photobucket.com/albums/v357/BallerX/DSCF1057.jpg)
I should be picking up a new(to me) frame this weekend. With title!! Woot! And the engine I'm waiting on pics of, so that will be next. Then it's off to strip & powder coat! Hooray!
good to see you were serious about tearing her down. Can't wait to see your progress. Keep us posted. :cheers:
great project have fun :thumb:
Quote from: 3imo on November 02, 2006, 09:30:12 AM
good to see you were serious about tearing her down.
I'm nothin but serious... ;)
I'll keep updating though. I'm prepping the exhaust now for a little repaint. It actually looks to be in suprisingly good shape. I've a shop lined up for the powder coating, everything's look pretty good. I'm thinking I should go with a new wiring harness just o eliminate the chance of broken wires. I also need to get the tank refinished.
Dissasembly is always so easy - but reassembly is always scary... :o :o
What an awesome log. Thanks for keeping us up to date.
Chilly
haha, theres hardly going to be any of the old bike in the finished project. Looks good and makes me want to go wrench on something.
Hey there RiderX,
So how much did you pay for this thing?
It seems like it needs work everywhere.
The more you take it apart and we see the photos, the more I cringe.
Why did you go this route instead of buying a bike in nice shape?
You probably would have spent a lot less money overall.
Just my opinion.
On the other hand, look at all the experience you are getting.
But it does look like an AWFUL LOT of work to bring it back and it will never be worth all the money you sink into it.
Good luck and best wishes,
Todd
A winter project is worth its weight in gold :cheers: Ya gotta have something to chase the blues away when there's no sunshine.
Quote from: RiderX on October 20, 2006, 05:01:40 PM
I hope this is redundant, but I just wanted to start a seperate thread for the rebuild project. I'll keep updating as I progress through the project and as you guys help me figure stuff out ;)...
The project bike is: 1991 Suzuki GS 500. I picked this bike up off of eBay for just over $200. I had to make a 2 or 3 hour road trip out to Philadelphia, PA to pick the bike up. Which was... interesting at best. Little did I know I would be diving head first into the slums of Flithadelphia to find this bike, let alone the crap I would have to go through just to find the guy's place. But alas, that's another story.
I drove 10hours to pick up my second GS500. front end wrecked.
I drove about 9 hours to pick my third GS. all in pieces.
The price he got is not so bad for a near complete GS500 restore prospect.
The engine is definitely cringe worthy as is the frame but sometimes you gotta do what you gotta do. When RiderX takes that bike out for the first time, he will know it was worth it.
I take more pride in my worthless cause projects than the new shaZam! I have in the driveway. It is way too easy to just buy something.
Quote from: Trwhouse on November 02, 2006, 02:27:55 PM
So how much did you pay for this thing?
It seems like it needs work everywhere.
The more you take it apart and we see the photos, the more I cringe.
Why did you go this route instead of buying a bike in nice shape?
You probably would have spent a lot less money overall.
Just my opinion.
On the other hand, look at all the experience you are getting.
But it does look like an AWFUL LOT of work to bring it back and it will never be worth all the money you sink into it.
I paid $230 for the bike from Philly. What did I get for $230? 3wheels - decent exhaust - good front forks - solid rear suspension and swingarm.
It does need work everywhere. There will actually be very little of this bike left.
I'm cringing too!
Come March, when the project is done and I fire this thing up, let it idle a bit, drop it into first and pull out of the drive way, all of this will be more than worth it. I could have bought something nicer. Hell, I could afford $100 a month on something BRAND NEW. However, when I'm twisting through the corners on the PA backroads, it is going to be on MY bike. In every sense, I will know every inch of this bike, and it will completly specific to me. Instead of buying my bike - I"ve built my bike.
I also get the to spend the time with family memebers and friends who want to help me out. There's nothing better than drinking a cold beer and turning wrenches on your bike with friends anr/or family. Most of the time were not even talking about the bike. I've got a VERY stressful job, and tooling around in the basement on projects like this are a great way for me to cool down. Rebuild projects like this are fun, and for me, its another excuse to hang out with people I like. That includes coming on this forum and asking questions, posting pics and begging for parts!!
:cheers:
hey nice project, mine's the other way, motor good; everything else trashed, I can't belive there are two junk looking GS's striped down right now with-in 30miles of one another :cheers:
maybe I should bring a 36pack one weekend
Thanks again RiderX for keeping this log going. I can't wait for the next update!
Is the tank relatively dent free? From the pictures it looks straight needing only some paint. How is the inside of the tank? On bikes like this...the tank is usually a total loss because of excessive rust and holes.
I'll get that air box and filter in the mail hopefully in the next week.
Great work!
-Turd.
Quote from: Jace009gs on November 03, 2006, 12:11:38 PM
I can't belive there are two junk looking GS's striped down right now with-in 30miles of one another :cheers:
maybe I should bring a 36pack one weekend
Ha! Cool man, where are you at?
Thanks Turd, I'll keep an eye out for the airbox. That's a bit into the distance on my priority list though. The tank is in good shape, I'm going to get it lines, the inside of the tank is a little rusty, but in suprisngly good shape.
Quote from: RiderX on November 03, 2006, 01:02:16 PM
The tank is in good shape, I'm going to get it lines, the inside of the tank is a little rusty, but in suprisngly good shape.
Good to hear. Good luck and get back to us soon!
-Turd.
Chambersburg PA
Well, just had a great little trip down into Maryland to meet up with GSTwins' own jared, to pick up a nice straight frame (w/title). Ended up picking up a few extras as well. Project is moving along nicely, and I can't wait to get this stuff off to powdercoat now. Of course... getting my hands on a clean, running engine would be kind of nice too...
But if any of you get the chance to deal with jared, I highly recommend it. Nice guy, and has a great stash of GS parts... good times!! :thumb:
Quote from: RiderX on November 03, 2006, 06:35:59 AMCome March, when the project is done and I fire this thing up, let it idle a bit, drop it into first and pull out of the drive way, all of this will be more than worth it. I could have bought something nicer.
That's the spirit! :thumb:
Small update. I now have a nice straight frame, a low miles running engine, and all the plastics I need. I'm going to have to wait a bit to start sending parts out to powder coat. Christmas present for other people apparently take priority over Christmas presents for me... :cookoo:
I'll be sending the tank out next week to get lined, and then its just a matter of getting all the parts in to poweder coat before I'm knee deep in reassembly problems. :cry: Lucky me...
There used to be a bike here... ???
(http://img.photobucket.com/albums/v357/BallerX/DSCF1116.jpg)
Much thanks to jared for the frame...
(http://img.photobucket.com/albums/v357/BallerX/DSCF1113.jpg)
Mmmm... bit parts...
(http://img.photobucket.com/albums/v357/BallerX/DSCF1118.jpg)
So with any luck, by the middle of January - begining of February, I should be putting things back together. :thumb:
Very cool, looks like things are coming right along!
-Turd.
Awesome! Keep posting for us. What's the weather like in February for you? Will you be able to take it out for a little spin?
Chilly
Weather isn't pretty bad in February. Nice and cold and a good bit of snow. But we usually get a break around mid - February where it gets into the mid-60s for about a week. I'm hoping that I can get a short ride in. Even if it's cold no big deal - so long as it's not snowing.
I'll keep the pics coming as I progress though. Thanks for the support guys!!
Looking good!
I hope you don't plan to keep those wheels white. What a PITA to keep clean! :mad:
Ha! Hell no!
I'm planning on painting the plastics and tank black, and getting the frame and wheels powder coated a nice dark grey. My tattoo artist is going to do some painting on the tank and plastics just to up the cool factor a bit...
That's some cool stuff!
Glad its coming along for you! Keep use posted!
Isn't it cool to have projects? Good outlet!
Well, since I haven't updated since NOVEMBER, I figured I would drag this thread out of the darkness!
Had some financial troubles surrounding the end/begining of the year, so not a lot of progress to show. I'm back on track now though, I've re-finished the tank and exhaust, this weekend will be the stripping and priming the frame. Due to the aforementioned financial woes, I've had to revaluate some of the project goals. I'm not going to go all out on a super nice finish, I'm just going to get it looking decent, my main goal here was just to get back to riding on the street again.
I'll post up some updated pics soon, as well as a list of all the small parts I'll be needing, I've started to write all that down now. Reassembly is soon!!!