Hi all, Im from Northern Ireland and I own a 89 GS 500. Over the past few months in my spare time, my friend and I have decided to fully restore my nearly 20 year old bike. Here is a quick blog of what all has been done during the strip down process, along with a few photographs.
Cheers
NI_Mike
Firstly, the bike as it began. Its doesnt look too bad when its altogether but alot of rust , wear and tear are hidden underneath it all. As the project progresses, I did ask myself several times is it worth it all?
(http://img4011.photobox.co.uk/3807829679c0e1396da9264eab07886a9135c33eee2217bb0a6f52f8eb377ed679035718.jpg)
(http://img4011.photobox.co.uk/46651598b1ecc364a948a70bf37ead2e05aca55b1f27689a8b859c37642dc6d1d11cb02d.jpg)
Even the stainless steel exhaust looks old and knackered. Its going to take alot of effort, sweat, pain, blood, spit, elbow grease and polish to bring it back to its former glory.
(http://img4011.photobox.co.uk/580600055017cd91c973f92a8e0570dfa29772911d694e7e28730891201d8933378b1d30.jpg)
(http://img4011.photobox.co.uk/954696747ed515ad65cf8ecbd16b4213d5b839579a084656630cc8a79a8bb0e63700248d.jpg)
What exactly is the side fairings there for? To make the bike look good or to hide whats underneath?
(http://img4011.photobox.co.uk/56426523f6757ab2aa5598bb2ec8ca58f26bd2837c7198c0a56f323ce14dda503dca966c.jpg)
(http://img4011.photobox.co.uk/371600184403d21aa4e7c7909f53ed1e1ff2c23dfae0efd8af57768e9a1a149ce7a701f0.jpg)
Nowhere on the bike is safe from weathering. Even hidden areas such as under the tank isnt safe. Alot more wear is found here too. Remember the locating for the throttle and choke cables. If your beast is running high revs when you turn, check the location of them.
(http://img4011.photobox.co.uk/82008683ffc5704d816700434cebf0c9f7d6c1b5e0f969b7ea0419946361903d56b17618.jpg)
As there are alot of nutts and bolts on the bike, its always a good idea to remember what goes where. As you can see, the wiring on the bike isnt the best.
(http://img4011.photobox.co.uk/57258271774d927861c5e91c31d468bd86908140932376551e8cefdd3ee17a645079a871.jpg)
(http://img4011.photobox.co.uk/27389587cab134ae2dded5e9f2fe6ea971f0cc9bc5406860d8e6327b60e61c868ea69912.jpg)
Alot of WD40 was used which reminds me, I must get onto them and get some sort of adorsement deal. Rear end took alot of WD40, as the rust had really set in. Next, as by magic the rear end just disappears.
(http://img4011.photobox.co.uk/535174602102d9480639e3a4d0c2ce51c1e57133c0a1769faf7dc64f598c0e655739fe09.jpg)
(http://img4011.photobox.co.uk/61623986252776feb502bf1f86d3d65d7687652d8e2d5def347e5d2c4ba477237529fd6e.jpg)
(http://img4011.photobox.co.uk/74454263a4a9ff2dc4abee8581602427f568c185878ffdc09f2cf70682672ff2a91354a2.jpg)
Oh and its a gonna!
(http://img4011.photobox.co.uk/228869712937069eaac4b3dde8e0078f38899b740d13ac9a842c12d5b33e96d7239f7bca.jpg)
(http://img4011.photobox.co.uk/06768984e4758ec132471b332bb0d86fa5d4b549c79296b199c972587aa754bfbc5f38f0.jpg)
(http://img4011.photobox.co.uk/917520099ad0ed8de1bb63272ec87a36b25b90077e56f43a24cd41e9a4a24035047418f3.jpg)
With the rear end out, you guessed it!!! Even more rust and bad stuff!
Next up was the removal of the engine mounting bolts and especially the one which sits right at the front of the end. The other ones came out with very little effort but there is always one!
(http://img4011.photobox.co.uk/7026170931e1bb52aad8425092fb2fd52a283341b377ea0db3a1ebb33ca09735b69cd536.jpg)
(http://img4011.photobox.co.uk/76292009f665851cd3780875dd468a45d6a1ce57329c0cc09b84fd1c0762507c70ce94ac.jpg)
We tried WD40 on it, heat and it wasnt going to shift. Under all that pressure we were putting on it, that section of the upper crank cover cracked. Its not visible on the pics.
(http://img4011.photobox.co.uk/45879104947a6961882bf11202701f9c981664216aaa7ad5436af116cdc642f8e9f6ca2c.jpg)
Next up was the removal of the front end and the wiring loom.
(http://img4011.photobox.co.uk/312040789a50970b5b7b7330c3ce94022f37e7a4bcc8dcbd98a4b93c2d98f6f21ee70030.jpg)
(http://img4011.photobox.co.uk/439341580d4a1b553a60a30c51b7ba66594831460b8274576a37d9881e71732e75143b50.jpg)
(http://img4011.photobox.co.uk/0074106212f3962211260d32010fca377bd68dcb4791e98061721dab93602c073c85304a.jpg)
Next the biggy job. Removing that front engine mounting bolt. One thing for it, the GRINDER! But first we had to get the engine out of the frame. The BOLT was left for another day!
(http://img4011.photobox.co.uk/166830775d8fce605c3790b77b4ea36d4206dcfd8877cd1d36eb15b4649bcc13b58e2ed2.jpg)
(http://img4011.photobox.co.uk/0112103027450965c44e2f22e7e355502df79ca77f676749c36bd6565715471b13bb6213.jpg)
And then all that was left, was an engine!
(http://img4011.photobox.co.uk/313020289711a7b9e675881310ee9e91ca271c010eb2644f3a5a075965fade0a940d1b0a.jpg)
Frame, bear and covered in the orange bad stuff.
(http://img4011.photobox.co.uk/24401356b238d9e52e4c5dcab35f0ed53848296e13977e92d01f7f2f698d8ff5159b27ec.jpg)
Next, was the removal of the stands and these things were a wee bit solid. Plenty of copper grease to get them moving and then whack them off.
(http://img4011.photobox.co.uk/1122283632a059bb73f29abfe807f9b682d6dce655173bc9085bcbe7f39333a1056563ae.jpg)
(http://img4011.photobox.co.uk/233914202027fe80844c9ece7604595848d02d6d5bf3b77a3b79f7a3a9fc1ff2fa23564e.jpg)
(http://img4011.photobox.co.uk/382838457b66348d42ddd04e30012e7c6f89dec0feed7f1903ebb7f2a3eceb147ab99bbd.jpg)
Next job, was to sort out all the pieces that were to be sent away for shot blasting and powder coating.
(http://img4011.photobox.co.uk/531513025d4eb5a8c8a5a8f8fc3f14071793062940e0fef6d98779421c9a14c46a12d999.jpg)
(http://img4011.photobox.co.uk/1064411735fef23133d8ccd9ac01658340a75c8d0d087fbc7508c2a7add8fa899e95dd87.jpg)
(http://img4011.photobox.co.uk/01331859320781e3c2e019d936908d361c5142a39a51e4ef634a292b6f04e4e9e5d41ab8.jpg)
With the bits to be sent away all sorted out, next up with the removal of that BOLT!
(http://img4011.photobox.co.uk/4643641880afa5cb9af2724fcc0014b28fb4889c17b6cdef3087c3311b6a4bee011f06c2.jpg)
(http://img4011.photobox.co.uk/19868901d15a38f9414a7f06f8190c1950fff9d520efe664b697f76ed6833f7eb5a5434d.jpg)
Next up was a tungston carbon drill bit which removed the rest of the bolt and casing from the upper crank case cover but that section had cracked under the stress of it being removed. Job - locate another upper crank case cover. That bit comes later.
Bits away to get shot blasted and powder coated. New bearings and other rebuild bits ordered up. Fun begins, trying to remember where everything went.
More of the stripdown photos can be found here - http://www.photobox.co.uk/album/7995256
Please tell me you're not going to sand and paint that tank. Simply gorgeous it looks. How bad is it ... inside and out. it looks great in the pic though.
Cool.
Buddha.
Wow! Thanks for taking the time to post this! :cheers:
Quote from: The Buddha on August 11, 2008, 07:50:44 AM
Please tell me you're not going to sand and paint that tank. Simply gorgeous it looks. How bad is it ... inside and out. it looks great in the pic though.
Cool.
Buddha.
Buddha. just wait until you the progress of it all and then you can tell me if it was all worth it or not.
Quote from: beRto on August 11, 2008, 08:08:36 AM
Wow! Thanks for taking the time to post this! :cheers:
No problem. Will be doing up something similar for the rebuild process this week.
Yea man.
BTW after you blast off all the rust, the bike will be like 20 lbs lighter. Rust can take up a lot of volume and in its layers it can take in water and dirt and really be very heavy.
Cool.
Buddha.
Quote from: The Buddha on August 11, 2008, 08:29:26 AM
Yea man.
BTW after you blast off all the rust, the bike will be like 20 lbs lighter. Rust can take up a lot of volume and in its layers it can take in water and dirt and really be very heavy.
Cool.
Buddha.
Very true and as well as that,
all of the nutts and bolts are now stainless - that should save a bit more on the weight lol.
Can't wait to see this progress.. :thumb:
Thanks for the photos.
very nice i plan on doing somthing similar this winter.
Very nice. Thanks for all the photos. I can't wait to see the finished product.
nice!
good luck with the project!
Can't wait for further progress and pics of course ;)
cheers
First job of the rebuild was to replace the upper crank case cover, as the mounting point had cracked. Although there is no oil at that point, it would have taken the look away from the finished job. Managed to source up a silver one, so decided to make the bottom silver and the top black. BUT during the process of the first engine rebuild, on turning the engine over onto its back to put in the oil filter, we heard something rattling about. Two heads had sheared off during the whole thing being torqued up and they were the 2 that sit in behind the oil filter, going through the bottom and then into the upper crank case.
(http://img4011.photobox.co.uk/07632137d60530d9596eb554a96529a94c41a0b8ea780f3399f4509b6be81672af487d6a.jpg)
(http://img4011.photobox.co.uk/51925617a0e4966c8784a5c5836e5b260a446ad3ce698f5b8d7b85565003966ec60c228d.jpg)
Luckily these hadnt locked in that tightly, so a pair of pliers and they were out again. Over to our local nutts and bolts place, who were able to match up a pair of replacements.
(http://img4011.photobox.co.uk/96124059d0c7e4974064e8f9868a241c3518ac35aab0cb9f59d83907313e4e6a9179c54a.jpg)
The first strip down and rebuild of the engine just took about 90 mins and of course that included tea & coffee breaks. Second time round, as the gaskets had totally bound and they were reusable, all of the gasket compound had to be cleaned off all parts and reapplied to a clean surface. The second rebuild took just over 40 mins to do - easy peasy since we had just done one less than an hour beforehand. lol
(http://img4011.photobox.co.uk/441603021bd5ed99193c2f898615554bffebb5a71a413d72ffcc609de39e186dfc204e15.jpg)
(http://img4011.photobox.co.uk/21990513a72c9cba0cc46adcb865ded999486463229e7ee2ec76d23a616ac8419d52d8db.jpg)
Frame and everything that had been powder coated had arrived. All bearings in the top yoke, wheels, rear suspension etc had to have excess powder coating removed and new bearings installed. The rear swing arm bearings gave the most problem, so I will add another post on at the end on how we got them out without having to buy an expensive blind hole bearing puller. ;-)
First up was to put the tyres back onto the rims, get the back & front end (new disc) built up, engine into the frame.
(http://img4011.photobox.co.uk/00641776a8e86f77e106ff0e1e6769e9e6a29e0fa80bec287ca6d0a3c5346fe5c392a9f1.jpg)
(http://img4011.photobox.co.uk/1642581828f3775290417a26df9ece24209e90f3b9b18dfaf03ec4ae25d12c8b30c20cfc.jpg)
(http://img4011.photobox.co.uk/265567591a49b84d824b565b98b564ecc53e1893df3054ce1b2a08aa3e3ce82f38801944.jpg)
Note in the picture below, I hadnt received the silver engine covers.
(http://img4011.photobox.co.uk/7030537306964945724c926220c2e8358ec6a0cb1f8cf54093673869e2de69083ad2a760.jpg)
(http://img4011.photobox.co.uk/561633611e6ca9b7551dda53d3fcbf455d9014048292e72af94ad5045e8ac4f61b47c287.jpg)
Tank was in a bad state of repair but not bad for its age. To be sorted out as it all goes along.
(http://img4011.photobox.co.uk/86737590d02130e976321b65801d7f52709935d83fc5fbe364b319d6d4031cc372344baf.jpg)
(http://img4011.photobox.co.uk/081497270a596e403077ae646b0e70acf9675e4b03de3f9fd802a81f67f92bdf06c568dd.jpg)
Next up was the strip down and refurb of the front caliper and break system. New pads installed as well.
(http://img4011.photobox.co.uk/918763791629d727381b8926cc81377ca3d02b4f468a89acc641ace749833a9edb5983df.jpg)
(http://img4011.photobox.co.uk/2659962647675154ef3778f212119949a44956ec605e588ef772992d5db3aec719e083cf.jpg)
(http://img4011.photobox.co.uk/323525640b2c74d344a5a7ab4482fb71a5fb4154e496ae17f482cdee4be9daf1e2de94a6.jpg)
The biggest problem before this all started was the wiring loom/harness, as the original one was cut and joined by the numerous other owners. Earthing and other problems were starting to happen so I managed to source a 89 one from New York. AND of course, you need a proper wiring diagram so that you can test everything as you go along. NO SENSE in putting it altogether to find out its just a lump of metal and nothing electrical works.
(http://img4011.photobox.co.uk/32698512da6684b3d03393001a781b29c65d78c92aed36c2542ffac99cf4ad2dca964c54.jpg)
(http://img4011.photobox.co.uk/5108543478587f1d86cc93cdb44942d9d2ecdf1b2978223113785e1bf4127b8a8a7d52c2.jpg)
(http://img4011.photobox.co.uk/733596004873996793b73ae66c4561f7c19f8da1da7fcb1f34f2ad0a5247b4a7f8da6abd.jpg)
(http://img4011.photobox.co.uk/8213756063cde107ceb2cf43bc72092d43090786f140fa8ce7ae9e444dac04b554119fa5.jpg)
(http://img4011.photobox.co.uk/963215732f192afc7d001bee385cd77df4c8356af431bef50208be9cf0d538fb6d0f8bfd.jpg)
(http://img4011.photobox.co.uk/41705782b772d373d3dc408e9a0e2ff4f5bae5d4a7c87b3853b01842a98cb9926a47adc1.jpg)
Next up, silver engine casings arrive. Time to get them fired on.
(http://img4011.photobox.co.uk/2907896348b12bf15a875c897edec04e33c4a38f24e458cf6fe1d2d5250bdb13e9fb5706.jpg)
(http://img4011.photobox.co.uk/0644221981ceb63b654eb7701559b9efc7f70cb55da4b6f70fe40bff47316aad3db8bff1.jpg)
Foot rests and stands installed with new springs.
(http://img4011.photobox.co.uk/57575738c2dabcb4d251a0fb2a507b1ede8ead65c5775861a66f4cb7766abaf003dc6cd8.jpg)
Side plastics fitted. Starting to look like a bike again.
(http://img4011.photobox.co.uk/099169113da984cf2318850f2d9e855bd6a53a2259d68e9c10fd1cadf92bb6dfad28dcc2.jpg)
(http://img4011.photobox.co.uk/06711733220f4c3e7e46a99e35ec99f8bd8f9ed7ea60096dfc92a978263885eed1fedceb.jpg)
One of the hardest things that I thought at the beginning to do, was the clean up of the badly weather exhaust system. I really didnt want to go out and buy a new system. I used a wire wheel brush on the air line, when the system was broken up. That was good for taking off the weathering. Next up, I used a mixture of brasso and petrol to eat down into the metal, with heavy coats of autosol. Alot of sweat, tears, elbow grease, spit and boot polish later, the exhaust looks like new again.
(http://img4011.photobox.co.uk/13059379a94b6eec5726daceec6c502372113ea2791e5752723167e0cdc1b60f61f8ab4c.jpg)
(http://img4011.photobox.co.uk/39633890ed270dcf61196bb252335f9c649015f513c0783335195432898561f3ecd8326b.jpg)
(http://img4011.photobox.co.uk/793052966261da84f364679ff88949e561f0bb91e1cc970c7e1005bee5df97dfecbbf5b2.jpg)
Now to get the exhaust onto the bike, alot of wiggling about but we got it on.
(http://img4011.photobox.co.uk/208199006b93e05b3026dbccbb6c6dd93004d61a3bba2a16c6f5a3c5cb341c9acde1393d.jpg)
(http://img4011.photobox.co.uk/0239827280d0d9e99c9abeabf814c6cfe59ed53daf0689dad6b73420b680d18c06d35375.jpg)
Next up was the belly pan fitting. The after market brackets were badly rusted, so these were cleaned up and painted black. Forgot to take a pic of them after they were painted but you can see the pan later on fitted to the bike.
(http://img4011.photobox.co.uk/38268377f40f85d0064ac945b9528dd856836d64dc6df0c7c0f9576aaeb59175f6db849a.jpg)
The bike rolled out so far. Decals, belly pan, mirrors still to go on and a good clean up still needed.
(http://img4011.photobox.co.uk/08842623dc68689ef659443ca2f748044585b29b3fb382638bfd0f0dde932acfe0a2d5cf.jpg)
(http://img4011.photobox.co.uk/12324988545c8a0887a28b699a47ba29dc27ae57ea6018766d90ecdfc77cbda50a0e78e6.jpg)
Belly pan and decals fitted. Still looking out for a nice set of chrome mirrors lol.
(http://img4011.photobox.co.uk/550672857ad5d9cda3615b93d120e49d529894ff8a973ae6e662a061919ba5ff92a83f8a.jpg)
(http://img4011.photobox.co.uk/8528765323eb0a3bf4c1f085f3c46b4b8f93671c327261f1e8431f438cb50dcef1045836.jpg)
Wow! She looks great!
Really wish I had a chin spoiler (and the time and patience to strip my whole bike)
Thats excellent. Ive stripped and rebuilt 2 bikes like this, right down to engine rebuild and new paint all round. Nothing can put into words how time consuming and difficult some of the tasks are. But the end result is worth every minute of your time with the blow torch and WD40 trying to get stuck stuff unstuck.
Good job!
Ni-mike -you are soooo bad ... you knew and still played it coy. nice bike ... I am very partial to black for my frames. But maybe I'd do the stock color on one and check.
Cool.
Buddha.
this thread should be linked in wiki and titled "GS500 overhaul"
excellent job man!
kudos
Is that the stock silver color? It looks almost pearly white in some of the pics.
Either way, it's purdy! :thumb:
WOW.. Very nice job. Well documented. :cheers:
Dude, how long did this take you??? :bowdown:
That is one beautiful bike! I'd love to do something like that to my bike some day...
Wow. The bike looks brand new! The silver engine covers are my favorite.
But seriously, how long did this take you??
Quote from: The Buddha on August 11, 2008, 01:02:09 PM
Ni-mike -you are soooo bad ... you knew and still played it coy. nice bike ... I am very partial to black for my frames. But maybe I'd do the stock color on one and check.
Cool.
Buddha.
Buddha, you loved it really if your honest! :icon_razz:
Quote from: kml.krk on August 11, 2008, 03:03:24 PM
this thread should be linked in wiki and titled "GS500 overhaul"
excellent job man!
kudos
I will change the thread name and then you can work away.
Quote from: pronator on August 11, 2008, 03:11:48 PM
Is that the stock silver color? It looks almost pearly white in some of the pics.
Either way, it's purdy! :thumb:
Im not sure if its the stock silver/grey colour but it was the colour of powder coat that I chose as I thought it would really stand out on the frame, wheels, rear end etc.
Quote from: scottpA_GS on August 11, 2008, 03:23:44 PM
WOW.. Very nice job. Well documented. :cheers:
Thanks but Im sure there is alot that I have missed out on. :2guns:
Quote from: mayhem on August 11, 2008, 09:37:59 PM
Dude, how long did this take you??? :bowdown:
Quote from: fred on August 12, 2008, 12:19:34 AM
That is one beautiful bike! I'd love to do something like that to my bike some day...
Its well worth the effort!
Quote from: mullethunter3 on August 12, 2008, 05:34:31 AM
Wow. The bike looks brand new! The silver engine covers are my favorite.
But seriously, how long did this take you??
Funny enough, I kept a spreadsheet and the total time approximately spent on it was 75 hours. This was a part time project where the bike only got worked on every few weekends due to work committments etc.
Still partial to black though. The silver my guy has is a very grainly looking one. Its smooth and high gloss, but looks like it has flakes in it. However you do candy blue (transparent blue) on it and its gorgeous.
Cool.
Buddha.
I just added the link to the WIKI.
it's located in the "RESTORATION" section.
I only added the link to this thread. If someone can do this more professionally, please do so.
Thanks
Kamel
Quote from: kml.krk on August 12, 2008, 10:53:21 AM
I just added the link to the WIKI.
it's located in the "RESTORATION" section.
I only added the link to this thread. If someone can do this more professionally, please do so.
Thanks
Kamel
cheers :cheers:
WOW!! excellent job man!! Now you just need to give that thing a fenderectomy.
WOW!!!! Just WOW!!! Incredible job!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! :cheers: :cheers: :cheers: :thumb: :thumb: :bowdown:
i have to tip my hat to you man it turned out beautiful but i am with budda on the frame color black would have looked pretty good
Quote from: tripleb on August 12, 2008, 05:55:52 PM
WOW!! excellent job man!! Now you just need to give that thing a fenderectomy.
Cheers but not sure what you mean about the fenderectomy :dunno_white:
Quote from: pandy on August 12, 2008, 09:08:35 PM
WOW!!!! Just WOW!!! Incredible job!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! :cheers: :cheers: :cheers: :thumb: :thumb: :bowdown:
Thanks, glad you like it.
Quote from: natewesselink on August 13, 2008, 02:23:16 AM
i have to tip my hat to you man it turned out beautiful but i am with budda on the frame color black would have looked pretty good
Alas, I have seen all years both UK ones and imports and yet to see a black frame as standard.
All that I wanted to do, was to return the bike to its former glory and standard of course.
Quote from: ni_mike on August 13, 2008, 03:01:36 AM
Cheers but not sure what you mean about the fenderectomy :dunno_white:
By "fenderectomy" we mean trimming or chopping off altogether the stock rear fender (or mudflap, or mudguard, or whatever), that rarely survives on a GS 500 after it's been rolling off the dealer's floor. :laugh:
EDIT: but, by the way, looking back at the pics and the size of UK numberplates, you can leave it as is as well. :thumb:Oh, and, oustanding job on that bike man. :thumb: :bowdown:
Quote from: simon79 on August 13, 2008, 03:36:00 AM
Quote from: ni_mike on August 13, 2008, 03:01:36 AM
Cheers but not sure what you mean about the fenderectomy :dunno_white:
By "fenderectomy" we mean trimming or chopping off altogether the stock rear fender (or mudflap, or mudguard, or whatever), that rarely survives on a GS 500 after it's been rolling off the dealer's floor. :laugh:
EDIT: but, by the way, looking back at the pics and the size of UK numberplates, you can leave it as is as well. :thumb:
Oh, and, oustanding job on that bike man. :thumb: :bowdown:
Cheers
wow that really got cleaned up nice
Quote from: Mdow on August 13, 2008, 06:01:26 AM
wow that really got cleaned up nice
Yes but to be totally honest, the photos dont do it any justice. Its looks better in real life. :thumb:
Quote from: natewesselink on August 13, 2008, 02:23:16 AM
i have to tip my hat to you man it turned out beautiful but i am with budda on the frame color black would have looked pretty good
As they say, you can please the people some of the time but you cant please everyone all of the time. :icon_twisted:
Some folks just don't grasp the concept of making it just like new. It's not what I would do or am doing, but I can appreciate the heck out of it (as well as keeping it just like new, which Trwhouse seems to have done quite well - OK, a few non-stock mods, but nothing radical):
(http://i14.photobucket.com/albums/a304/trwhouse/GS500ESept307atClaySChool.jpg)
http://gstwins.com/gsboard/index.php?topic=43562.msg488563#msg488563 (http://gstwins.com/gsboard/index.php?topic=43562.msg488563#msg488563)
I must say, these are beautiful. Nice work. And....................I am a firm believer in NOT doin' that "fenderectomy". I love the bike unmodified so to speak.......as is. I, however, will sometime soon I hope, get my entire pipes and muffler chromed. I have gotten the decals removed from the side panels. I never could stomach them. Had them repainted at a body shop. I want a "Johnny Castaway" scene painted on them (side panels) in detail. It is my understanding that a small scene with him on the island and a few palm trees
could easily run over 300 bucks and I live in a "not too expensive part of the USA". Any of you that have any insight of airbrush or art brush detail painting that could give me any input would be appreciated. I keep this bike in storage and intend on it being my "retirement" put put bike around town. Mine is the Y2K "EY" model. Again.......exellent effort and results.
p.s. there was a guy that made those side plate covers (points cover?) from polished stainless with the old Suzuki styled "S" that I wanted but his link is dead. Damn they were fine looking.
Quote from: DoD#i on August 13, 2008, 04:10:03 PM
Some folks just don't grasp the concept of making it just like new. It's not what I would do or am doing, but I can appreciate the heck out of it (as well as keeping it just like new, which Trwhouse seems to have done quite well - OK, a few non-stock mods, but nothing radical):
http://gstwins.com/gsboard/index.php?topic=43562.msg488563#msg488563 (http://gstwins.com/gsboard/index.php?topic=43562.msg488563#msg488563)
Making it like new was the whole idea of the overhaul, otherwise I would have just left it to rust to bits.
Quote from: Revere2 on August 13, 2008, 07:35:59 PM
I must say, these are beautiful. Nice work. And....................I am a firm believer in NOT doin' that "fenderectomy". I love the bike unmodified so to speak.......as is. I, however, will sometime soon I hope, get my entire pipes and muffler chromed. I have gotten the decals removed from the side panels. I never could stomach them. Had them repainted at a body shop. I want a "Johnny Castaway" scene painted on them (side panels) in detail. It is my understanding that a small scene with him on the island and a few palm trees
could easily run over 300 bucks and I live in a "not too expensive part of the USA". Any of you that have any insight of airbrush or art brush detail painting that could give me any input would be appreciated. I keep this bike in storage and intend on it being my "retirement" put put bike around town. Mine is the Y2K "EY" model. Again.......exellent effort and results.
p.s. there was a guy that made those side plate covers (points cover?) from polished stainless with the old Suzuki styled "S" that I wanted but his link is dead. Damn they were fine looking.
Those decals you mention, sound cool. Wouldnt mind getting my mitts on some of those if I didnt already have a replacement set.
+1 on the Very Nice Restoration, it really looks great!
Tony
Quote from: TonyKZ1 on August 14, 2008, 06:18:33 AM
+1 on the Very Nice Restoration, it really looks great!
Tony
Cheers Tony :thumb:
holy freakin shaZam! :o :o :o :o Just 75 hours and it looks amazing. :bowdown: It took me 12 long hours just to replace the drive sprocket and chain :oops:
You know your stuff too damn well :cheers:
Can anyone explain the meaning of the "slingshot" legend on the sidecovers? Does this refer to the carbs? I see this all the time but have no idea what it means.
The slingshot moniker is for the first gen GSXR 750, It also came in dry clutch - the limited edition. Then suzuki must have printed a few million stickers saying slingshot ... and when they got sued for making a dangerous sling shot in the US, they slapped it on all euro bikes for a few years. Or ... close enough.
Cool.
Buddha.
Quote from: astroaru on August 14, 2008, 01:59:33 PM
holy freakin shaZam! :o :o :o :o Just 75 hours and it looks amazing. :bowdown: It took me 12 long hours just to replace the drive sprocket and chain :oops:
You know your stuff too damn well :cheers:
There was 2 of us working on it, on a part time / weekend basis. Both dismantling, putting stuff in named boxes ready for rebuilding and replacing stage. Also, having all of the tools to hand also helps as well as being able to come up with expensive tool alternatives to keep it all moving along too.
Quote from: commuterdude on August 14, 2008, 02:27:44 PM
Can anyone explain the meaning of the "slingshot" legend on the sidecovers? Does this refer to the carbs? I see this all the time but have no idea what it means.
Slingshot is just like a model as far as I know.
Quote from: The Buddha on August 14, 2008, 04:25:36 PM
The slingshot moniker is for the first gen GSXR 750, It also came in dry clutch - the limited edition. Then suzuki must have printed a few million stickers saying slingshot ... and when they got sued for making a dangerous sling shot in the US, they slapped it on all euro bikes for a few years. Or ... close enough.
Cool.
Buddha.
Aye something like that. lol
Forgot to mention, that everything was copper slipped during the rebuild process! :cheers:
Thread bump for those who havent read the thread. :icon_lol:
Forgot to mention, that everything was copper slipped during the rebuild process!
OK what is that ???
Cool.
Buddha.
Quote from: The Buddha on August 18, 2008, 06:45:18 AM
Forgot to mention, that everything was copper slipped during the rebuild process!
OK what is that ???
Seems like a UK-ism for what you might know as anti-seize, at a guess. At least, my high temp anti-seize is copper-flake filled, and using it on anything I take apart so it's easier to take apart the next time is SOP for my mechanical endeavours.
<edit - add tale> This made the guy salvaging (in 2006) the rear springs off my 1987 truck (which I changed in 1994) both surprised, and quite happy. At various times it's also directly benefitted me, and it takes little time or expense to do - one can of the stuff is a lifetime supply if working on your own projects only, unless you have huge projects. I own two cans, but that's only because I could not find one until after I bought the other, and it allows me to stash one in both places I usually do mechanical work.</edit>
Quote from: DoD#i on August 18, 2008, 07:10:40 AM
Quote from: The Buddha on August 18, 2008, 06:45:18 AM
Forgot to mention, that everything was copper slipped during the rebuild process!
OK what is that ???
Seems like a UK-ism for what you might know as anti-seize, at a guess. At least, my high temp anti-seize is copper-flake filled, and using it on anything I take apart so it's easier to take apart the next time is SOP for my mechanical endeavours.
thats exactly what it is.
Quote from: DoD#i on August 18, 2008, 07:10:40 AM
Quote from: The Buddha on August 18, 2008, 06:45:18 AM
Forgot to mention, that everything was copper slipped during the rebuild process!
OK what is that ???
<edit - add tale> This made the guy salvaging (in 2006) the rear springs off my 1987 truck (which I changed in 1994) both surprised, and quite happy. At various times it's also directly benefitted me, and it takes little time or expense to do - one can of the stuff is a lifetime supply if working on your own projects only, unless you have huge projects. I own two cans, but that's only because I could not find one until after I bought the other, and it allows me to stash one in both places I usually do mechanical work.</edit>
We have a tub of the more solid stuff as well as a spray can version for those harder to reach place. :2guns:
Quote from: ni_mike on August 18, 2008, 04:52:48 AM
Thread bump for those who havent read the thread. :icon_lol:
Still to add on those tools/variations that were used instead of purchasing the expensive alternatives. Coming soon.
Quote from: commuterdude on August 14, 2008, 02:27:44 PM
Can anyone explain the meaning of the "slingshot" legend on the sidecovers? Does this refer to the carbs? I see this all the time but have no idea what it means.
The term Slingshot does relate to the carbs. Suzuki started using a brand new Mikuni design in the late 80s on the GSXRs and the then brand new GS5 (which borrowed its design style from the GSXRs). The carbs had vacuum operated sliders which in cross-section resembled a Slingshot. At the time buzzwords and acronyms were in fashion and popular with the manufacturers and buyers..........so the name was addopted to "sex-up" the bike.
Quote from: sledge on August 20, 2008, 03:32:44 AM
Quote from: commuterdude on August 14, 2008, 02:27:44 PM
Can anyone explain the meaning of the "slingshot" legend on the sidecovers? Does this refer to the carbs? I see this all the time but have no idea what it means.
The term Slingshot does relate to the carbs. Suzuki started using a brand new Mikuni design in the late 80s on the GSXRs and the then brand new GS5 (which borrowed its design style from the GSXRs). The carbs had vacuum operated sliders which in cross-section resembled a Slingshot. At the time buzzwords and acronyms were in fashion and popular with the manufacturers and buyers..........so the name was addopted to "sex-up" the bike.
Cheers for that update sledge :)
Quote from: sledge on August 20, 2008, 03:32:44 AM
Quote from: commuterdude on August 14, 2008, 02:27:44 PM
Can anyone explain the meaning of the "slingshot" legend on the sidecovers? Does this refer to the carbs? I see this all the time but have no idea what it means.
The term Slingshot does relate to the carbs. Suzuki started using a brand new Mikuni design in the late 80s on the GSXRs and the then brand new GS5 (which borrowed its design style from the GSXRs). The carbs had vacuum operated sliders which in cross-section resembled a Slingshot. At the time buzzwords and acronyms were in fashion and popular with the manufacturers and buyers..........so the name was addopted to "sex-up" the bike.
Naaaaa ... I like the few million extra slingshot stickers idea better. Besides the diaphragms all look slingshotty even before the GS style ones. Kidding.
Cool.
Buddha.
Quote from: The Buddha on August 20, 2008, 07:13:30 AM
Quote from: sledge on August 20, 2008, 03:32:44 AM
Quote from: commuterdude on August 14, 2008, 02:27:44 PM
Can anyone explain the meaning of the "slingshot" legend on the sidecovers? Does this refer to the carbs? I see this all the time but have no idea what it means.
The term Slingshot does relate to the carbs. Suzuki started using a brand new Mikuni design in the late 80s on the GSXRs and the then brand new GS5 (which borrowed its design style from the GSXRs). The carbs had vacuum operated sliders which in cross-section resembled a Slingshot. At the time buzzwords and acronyms were in fashion and popular with the manufacturers and buyers..........so the name was addopted to "sex-up" the bike.
L 8) L
Naaaaa ... I like the few million extra slingshot stickers idea better. Besides the diaphragms all look slingshotty even before the GS style ones. Kidding.
Cool.
Buddha.
Thread bump. Typing up the problems encountered as I speak. :icon_mrgreen:
List of what all was purchased and replaced/refurbished on the bike.
Stainless steel hex heads nutts, bolts & washers
Rear shock
Complete rear brake system & pads
Cush drive rubbers
Chain and sprockets
Foot rests
Swing arm bearings
Steering head bearing
Shock linkage
Chain adjusters
Engine mounting bolts
Head light
Adjustable forks
Front disc
Wiring loom
Seat release cable
Upper crank case cover
Side panels (silver)
Front brake pads
Paints
Engine casing stainless steel hex head bolts & washers
HT Leads
Oil & Filter
Plugs
Battery
Torque arm
Mirrors
Belly pan brackets - clean down and repainted originals
Decals
Full engine rebuild kit
Stand springs
Clutch cable
Carbs
Engine top cover
Fuel tap and fuel lines
Rev counter cable
Rev counter cable engine housing
Gear box selectors
Fork Seals
Fairing rubber cushions
Problems encountered when doing the rebuild.
Firstly, I had all of the frame, steering bearings etc already ordered and ready for when the powder coated pieces came back. The main job was to remove the bearings and the slight amount of powder coat on top of them. The most difficult were those in the swing arm - the main ones. As we didnt have a blind whole bearing puller, we had to come up with something similar that done the same job.
This is always something to remember, either take the bearings out and fill in the wholes, or have replacements for those that are going to get powder coated.
We used these rawl bolts to remove the swing arm bearings.
(http://img4011.photobox.co.uk/48323108f2e1f77a51dfbe4d5fd4ed269b8f7e2aa6257f6bac4e2212e6375f06ddc4646e.jpg)
Forgot to mention that these were used along with a puller to remove the swing arm bearings. :icon_rolleyes:
what does everyone else think of this overhaul/rebuild? :dunno_white:
I think to make it interesting you should post a picture of brooke burke.
:)
I like it. I love the pics... more more more....
Quote from: alois71 on August 28, 2008, 11:46:15 AM
I think to make it interesting you should post a picture of brooke burke.
:)
I like it. I love the pics... more more more....
More strip down pics here - http://www.photobox.co.uk/album/7995256 (http://www.photobox.co.uk/album/7995256)
More rebuild pics here - http://www.photobox.co.uk/album/7995547 (http://www.photobox.co.uk/album/7995547)
Beautiful work! Wish my project would move along that quickly!
Quote from: utgunslinger13 on August 28, 2008, 12:52:47 PM
Beautiful work! Wish my project would move along that quickly!
Cheers! It all takes time. Best plan of action, is to strip the bike down and place the pieces into labelled containers and as you are dismantling, make a comprehensive list of what needs replacing. When thats finished and the frame etc is away getting painted/powder coated, get those bits ordered up ready for the rebuild. When everything is sitting there, its alot quicker to put it back together again, rather than ordering as and when you need stuff. :cheers:
Update from last week, bike fired up again and it sounds really mean. Defo well worth doing the complete rebuild when replacing the upper crank case cover. 8)
Just noticed a small leak (the odd drip) which seems to be coming from around the gear lever area. Anyone any ideas on how to fix this or what needs changed? Cheers. :thumb:
Quote from: ni_mike on August 29, 2008, 11:57:38 AM
Just noticed a small leak (the odd drip) which seems to be coming from around the gear lever area. Anyone any ideas on how to fix this or what needs changed? Cheers. :thumb:
Anyone? :dunno_white:
Quote from: ni_mike on August 29, 2008, 11:57:38 AM
Just noticed a small leak (the odd drip) which seems to be coming from around the gear lever area. Anyone any ideas on how to fix this or what needs changed? Cheers. :thumb:
Sorry, I didn't notice the question before.
Some bikes "leak" when built up chain grease melts while riding and then drips. Since your bike was just rebuilt, it seems safe to assume you are expereiencing a legitimate leak.
In that case, here are some threads that may help:
http://gstwins.com/gsboard/index.php?topic=24829.0
http://gstwins.com/gsboard/index.php?topic=40007.0
http://gstwins.com/gsboard/index.php?topic=31678.0
http://gstwins.com/gsboard/index.php?topic=31513.0
http://gstwins.com/gsboard/index.php?topic=39454.0
http://gstwins.com/gsboard/index.php?topic=37475.0
I couldn't find a HOW TO, but I'm pretty sure there is one out there (maybe in the FAQ?); I suggest you spend a few minutes searching for better info.
Quote from: beRto on August 31, 2008, 09:01:38 AM
Quote from: ni_mike on August 29, 2008, 11:57:38 AM
Just noticed a small leak (the odd drip) which seems to be coming from around the gear lever area. Anyone any ideas on how to fix this or what needs changed? Cheers. :thumb:
Sorry, I didn't notice the question before.
Some bikes "leak" when built up chain grease melts while riding and then drips. Since your bike was just rebuilt, it seems safe to assume you are expereiencing a legitimate leak.
In that case, here are some threads that may help:
http://gstwins.com/gsboard/index.php?topic=24829.0
http://gstwins.com/gsboard/index.php?topic=40007.0
http://gstwins.com/gsboard/index.php?topic=31678.0
http://gstwins.com/gsboard/index.php?topic=31513.0
http://gstwins.com/gsboard/index.php?topic=39454.0
http://gstwins.com/gsboard/index.php?topic=37475.0
I couldn't find a HOW TO, but I'm pretty sure there is one out there (maybe in the FAQ?); I suggest you spend a few minutes searching for better info.
Cheers, I will check them out and post back with an update shortly! :cheers:
Thread bump for anyone who hasnt seen the overhaul. 8)
I like the GI Joe looking stripes on the back of those old GS's. This thread makes me wish I could afford to get an old one and rebuild this winter.
Quote from: nascarkeith on September 10, 2008, 04:13:41 PM
I like the GI Joe looking stripes on the back of those old GS's. This thread makes me wish I could afford to get an old one and rebuild this winter.
Maybe you should, then flog it on and fund a bigger project. 8)
Quote from: ni_mike on September 12, 2008, 12:40:07 PM
Quote from: nascarkeith on September 10, 2008, 04:13:41 PM
I like the GI Joe looking stripes on the back of those old GS's. This thread makes me wish I could afford to get an old one and rebuild this winter.
Maybe you should, then flog it on and fund a bigger project. 8)
Im looking at a GSX1400 as the next project to the GS.
Update - bike finished and mot'd. Some final photos uploaded and there was no oil leak, turned out to be the WD40 used to clean the engine, had collected and caused the drip.
http://www.photobox.co.uk/album/7995547 (http://www.photobox.co.uk/album/7995547)
Pics should appear shortly when they decide they want to appear lol O0
^^^^^
link no worky :cry:
Quote from: kml.krk on September 30, 2008, 10:07:39 AM
^^^^^
link no worky :cry:
Just checked this and the link is working. Try again. :dunno_white:
(http://img3014.photobox.co.uk/05269650428f54d9a3898727f37c75ce80e564a749e13d6366b0e57d81fdbcefd1fa8513.jpg)
(http://img3014.photobox.co.uk/513791762c85bcde6233c82f2a1e1f87020ad54854bc1cb2e6cac04450b882f66ce08952.jpg)
(http://img3014.photobox.co.uk/58110352d8014f67c1e998ff744c8870cb6b325fd28d13871a7228f9e4decd9368b75e71.jpg)
(http://img3014.photobox.co.uk/2008265707549c246882dca96c6ff9cd3a74bae0bdbfb9ad0d92ecce2651c88dad914f75.jpg)
(http://img3014.photobox.co.uk/9509371118373e90f0408d32c5534e0a02c72cab17800d9580fce411390fee158d624c40.jpg)
(http://img3014.photobox.co.uk/364586986181345c47576053f3c74f5461822e4020d9343e4b8416a75cc472b25e9bb50a.jpg)
(http://img3014.photobox.co.uk/348577084b85ef1fb00f5f5735da832de4ebccb74dd8b411e3a2988180a5a438f21e521d.jpg)
(http://img3014.photobox.co.uk/225481498df27b5f79de73a39c6923c0a15903339b4a4357b41ec968070c7fd9d08ae44e.jpg)
(http://img3014.photobox.co.uk/732742352b7e9a51aed273dfa6df9aff4d91a007d433b22c89fc86d85b681b18a7831806.jpg)
(http://img3014.photobox.co.uk/27212644c19c217c1ddeb6c2a99a277be7c63a469c53f7c17a3b675d55d87758f9c11456.jpg)
(http://img3014.photobox.co.uk/593878854e7986b1e2c115b53a53bde6973ef58ee4a6fec59a69e86cc215ab5742ae68d1.jpg)
Great transformation! Rusty pile turned out as one of the prettiest GSs I've seen :thumb:
the 2-toned front fender is pretty cool
Quote from: Affschnozel on October 19, 2008, 05:36:27 AM
Great transformation! Rusty pile turned out as one of the prettiest GSs I've seen :thumb:
Cheers, glad you like all the effort that has been put into getting the bike back to its former and proper glory.
Quote from: LOUiE on October 19, 2008, 09:17:41 AM
the 2-toned front fender is pretty cool
Cheers, as far as I know, thats the way it was in 89 when it was manufacturered. :thumb:
Quote from: ni_mike on August 31, 2008, 01:56:32 AM
Quote from: ni_mike on August 29, 2008, 11:57:38 AM
Just noticed a small leak (the odd drip) which seems to be coming from around the gear lever area. Anyone any ideas on how to fix this or what needs changed? Cheers. :thumb:
Anyone? :dunno_white:
O-ring/seal perhaps?
Quote from: yamahonkawazuki on October 20, 2008, 02:07:23 AM
Quote from: ni_mike on August 31, 2008, 01:56:32 AM
Quote from: ni_mike on August 29, 2008, 11:57:38 AM
Just noticed a small leak (the odd drip) which seems to be coming from around the gear lever area. Anyone any ideas on how to fix this or what needs changed? Cheers. :thumb:
Anyone? :dunno_white:
O-ring/seal perhaps?
No, turned out to be some WD40 that had collected on the belly pan from cleaning down the engine and frame near the end of the project.
Thread bump
dam thats hot which exhuast is that? its diiirty
That thing is amazing! Looks like it just rolled of the showroom floor! Nice restoration. :bowdown:
Quote from: hotrodstu77 on October 20, 2008, 10:45:29 AM
dam thats hot which exhuast is that? its diiirty
Nexus full stainless. Its about 8 years old now, found the original reciept for it.
Quote from: bucks1605 on October 20, 2008, 11:03:48 AM
That thing is amazing! Looks like it just rolled of the showroom floor! Nice restoration. :bowdown:
Cheers, alot of effort but im sure you'll agree, it was well worth it! :cheers:
Doesnt look bad for a nearly 20 year old bike :2guns:
Quote from: ni_mike on October 24, 2008, 12:12:44 PM
Doesnt look bad for a nearly 20 year old bike :2guns:
BUMP! :o
Bad ass, what year is it and do you have the befoe pics or did I miss them? :cheers:
Quote from: seanathin48 on November 05, 2008, 03:14:54 AM
Bad ass, what year is it and do you have the befoe pics or did I miss them? :cheers:
89 and if you go back to page 1, all the pictures are up there. check it out and reply back again.
man I have just looked again at the first page of this post to refresh my memory.
By the time you have finished your project I have already forgotten how your bike looked before restoration... :oops: :oops:
all I have to say is: AMAZING ;) you and friend of yours did a great job!! I can't imagine how much work and effort you guys have put into this bike!!
she looks absolutely georgeous!!
Nice Work! I'm doing the same thing right now. I wish I had of taken pic's now :cry: I will post up some later. I've decided to do all the painting myself, can you tell me...Does the engine casing clear 300 degrees? Id rather not use high heat paint if I can avoid it....I know the exhaust will have to be high heat (Just going to replace it anyway). Well, It's nice to see someone else is a crazy as I am. My 89 is down to the smallest bolt right now...including the engine. I have stripped it bare....now comes the hard part. Thanks for the visual incouragment!!
Quote from: playmemuzk on November 09, 2008, 05:26:35 PM
Nice Work! I'm doing the same thing right now. I wish I had of taken pic's now :cry: I will post up some later. I've decided to do all the painting myself, can you tell me...Does the engine casing clear 300 degrees? Id rather not use high heat paint if I can avoid it....I know the exhaust will have to be high heat (Just going to replace it anyway). Well, It's nice to see someone else is a crazy as I am. My 89 is down to the smallest bolt right now...including the engine. I have stripped it bare....now comes the hard part. Thanks for the visual incouragment!!
Cheers for the comments playmemuzk - I would recommend the high heat paint to be honest, cus you dont want to go to all that trouble for the paint not to take the heat, having to take the engine out again and repaint. Its alot of hassle for nothing. Glad this give you the encouragement to go for the full rebuild / overhaul.
All the best
Mike
Just a thread bump up for those who havent read the thread. :icon_mrgreen:
i currently have a heat siezed engine in mine. cant seem to crack the head off. any suggestions? cant find out exactly whats siezed until its off....
A bit of a thread bump up for those who havent seen the thread.
Also setup a blog @ www.orchardcountybikes.co.uk (http://www.orchardcountybikes.co.uk) as we are in the process of refurbing a 1988 GSX 1100F Katana, powerscreen model.