Before I start I'll just say I don't know anything about this bike (or bikes in generally really). I'm more of a car kinda guy, hence the thread title!
Although I really should buy a Haynes manual atleast. :icon_mrgreen:
I Bought this bike last year for £500 with 17k miles. I decided to take it apart and clean everything and put it back together including replacing a few parts such as the headlight, both mirrors (current ones are ugly chrome ones, kinda looks like an insect with them on) and a few other bits.
Here are a few (well more than a few, maybe too many as most of them I took just to aid me in putting the bike back together) pictures of the current stripdown. In no particular order
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0536.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0535.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0534.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0533.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0532.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0531.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0530.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0529.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0528.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0527.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0526.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0525.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0524.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0523.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0522.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0521.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0520.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0519.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0518.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0510.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0517.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0516.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0515.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0514.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0513.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0512.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0511.jpg)
Ofcourse it wasn't long before I hit my first problem ... trying to remove the front engine mount as you can see in my thread http://gstwins.com/gsboard/index.php?topic=60114.0 (http://gstwins.com/gsboard/index.php?topic=60114.0)
I have just purchased some new carbon fibre 'look' clip on mirrors:
(http://s.ecrater.com/stores/149231/4ba22714bc32c_149231n.jpg)
(http://s.ecrater.com/stores/149231/4ba2272935f23_149231b.jpg)
I think they look great, really happy with them, I can provide a link if anyone likes them.
Thanks for looking, next update should include me having got that bastard have the bolt off! :)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0510.jpg)
:dunno_white:
Thanks for all the pics. Looks like you got a project going there.
Wow! I never saw raisers for the Euro short clip ons. They look OEM. Do you know anything about them? I'd love to have them as a part of my collection. Trade? Headlight maybe?
Started the same way here.
I wasnt mechanically new, just new to workin on bikes.
I found everything but the engine to be pretty easy to work with.
So a lil advice, when you get to the engine work if you have any.
Be veryyyy careful.
and come here for any help needed.
As I've done some mistakes on mine due to lack of knowledge and its cost me... Big time!
like one example.
The 8 bolts that tighten down the upper engine to the bottom.
4 are on the outside, 4 inside.
The 4 on the outside are just Slightly longer then the ones on the inside.
Unless you Really look, you cant really tell... or at least I didnt until I went through alot with that specifically. hahaha
Good luck with the rebuild!
Quote from: adidasguy on April 18, 2012, 12:23:31 PM
Wow! I never saw raisers for the Euro short clip ons. They look OEM. Do you know anything about them? I'd love to have them as a part of my collection. Trade? Headlight maybe?
I always thought the front end looked 'unique'! I don't know much about them apart from I kinda need them since I'm 6'5 tall it would hurt my back without them! :icon_lol:
If I ever see any or change handlebars you will be the first person to know if you're still interested :)
Quote from: Tombstones81 on April 18, 2012, 12:46:57 PM
Started the same way here.
I wasnt mechanically new, just new to workin on bikes.
I found everything but the engine to be pretty easy to work with.
So a lil advice, when you get to the engine work if you have any.
Be veryyyy careful.
and come here for any help needed.
As I've done some mistakes on mine due to lack of knowledge and its cost me... Big time!
like one example.
The 8 bolts that tighten down the upper engine to the bottom.
4 are on the outside, 4 inside.
The 4 on the outside are just Slightly longer then the ones on the inside.
Unless you Really look, you cant really tell... or at least I didnt until I went through alot with that specifically. hahaha
Good luck with the rebuild!
Yeah thanks for the advice, iv'e read your project from the beginning :thumb:
Take lots pf pictures before you take things apart AND as you take things apart. It will help knowing where they go back. I did that for the donor bike for Phenix's engine. When I put the engine in Phenix, the photos reminded me how everything is routed.
Have plenty of small parts bins and baggies. Sort things and label things.
Clean all parts - remove rust and polish them. I use a vibrating parts cleaner. A small one with all supplies is $100 US. I'm sure you can get them over there.
Invest in assortments of stainless steel screws. When you reassemble things, use SS where possible. It looks cool and will last longer.
If something is damaged or doesn't look as good as it should, replace it. Don't be afraid of bike breakers. I use lots of newer parts from newer bikes on my '92 and 94 bikes and a LOT in building Phenix. There is so much compatibility from 1989 to the present that you can pick and chose the best parts.
Buy a couple "box-o-bolts" from bike breakers. as they take a bike apart, they throw the nuts, bolts and other stuff in a box and sell that grab bag of stuff. GET SOME! you'll find all kinds of parts and bolts that you lost or ones that were not good enough to put back on your bike.
Never be afraid to ask questions. Post pictures so we know what you're talking about.
Hope this advice helps.
I never thought I could build a bike. I did! All the info on this board has helped so much. I would have been lost without it.
Quote from: adidasguy on April 19, 2012, 02:27:37 AM
Take lots pf pictures before you take things apart AND as you take things apart. It will help knowing where they go back. I did that for the donor bike for Phenix's engine. When I put the engine in Phenix, the photos reminded me how everything is routed.
Have plenty of small parts bins and baggies. Sort things and label things.
Clean all parts - remove rust and polish them. I use a vibrating parts cleaner. A small one with all supplies is $100 US. I'm sure you can get them over there.
Invest in assortments of stainless steel screws. When you reassemble things, use SS where possible. It looks cool and will last longer.
If something is damaged or doesn't look as good as it should, replace it. Don't be afraid of bike breakers. I use lots of newer parts from newer bikes on my '92 and 94 bikes and a LOT in building Phenix. There is so much compatibility from 1989 to the present that you can pick and chose the best parts.
Buy a couple "box-o-bolts" from bike breakers. as they take a bike apart, they throw the nuts, bolts and other stuff in a box and sell that grab bag of stuff. GET SOME! you'll find all kinds of parts and bolts that you lost or ones that were not good enough to put back on your bike.
Never be afraid to ask questions. Post pictures so we know what you're talking about.
Hope this advice helps.
I never thought I could build a bike. I did! All the info on this board has helped so much. I would have been lost without it.
+1
Quote from: adidasguy on April 19, 2012, 02:27:37 AM
Take lots pf pictures before you take things apart AND as you take things apart. It will help knowing where they go back. I did that for the donor bike for Phenix's engine. When I put the engine in Phenix, the photos reminded me how everything is routed.
Have plenty of small parts bins and baggies. Sort things and label things.
Clean all parts - remove rust and polish them. I use a vibrating parts cleaner. A small one with all supplies is $100 US. I'm sure you can get them over there.
Invest in assortments of stainless steel screws. When you reassemble things, use SS where possible. It looks cool and will last longer.
If something is damaged or doesn't look as good as it should, replace it. Don't be afraid of bike breakers. I use lots of newer parts from newer bikes on my '92 and 94 bikes and a LOT in building Phenix. There is so much compatibility from 1989 to the present that you can pick and chose the best parts.
Buy a couple "box-o-bolts" from bike breakers. as they take a bike apart, they throw the nuts, bolts and other stuff in a box and sell that grab bag of stuff. GET SOME! you'll find all kinds of parts and bolts that you lost or ones that were not good enough to put back on your bike.
Never be afraid to ask questions. Post pictures so we know what you're talking about.
Hope this advice helps.
I never thought I could build a bike. I did! All the info on this board has helped so much. I would have been lost without it.
I appreciate the words of wisdom, thanks :thumb:
Little update, the mirrors arrived, but when you look in the glass it makes everything tiny and seem further away which is the last thing you want when on a bike! So I'll be getting some different ones. Its just not worth using them and having an accident cause of them.
Anyway heres a checklist of things I need to do and buy:
Completly strip the bike
Clean EVERY single part on the bike, or replace it if I have to (Thats alot of parts)
Clean plastics up aswell
New 14t sprocket
New headlight
New handlebar grips
New Brake Lever (Old one is snapped 3/4 way across)
Soak chain in oil to preserve it
Sand down the frame
Sand down any other metal bits in prep for paint
Prime everything with rust protection primer
Paint frame silver, laquer etc.
Clean & rejet carb
Rebuild suspension with new oil
Make the fuel tank look prettier (not sure best way to do it, is has a scrape and dent with rust coming through, any suggestions?)
New Fork Oil
New engine oil
New brake fluid
New nuts and bolts throughout
I'll add to list as I go along, theres some more stuff I forgot
I've took some more pictures I'll upload and post tomorrow morning.
Does anyone know how much fork oil to use and what grade works best?
You measure the oil level. best source of info is a service manual, Haynes or Clymer manual.
Oil level can vary depending on what you want for the feel. 10w is suggested. Many of us go 15w.
From the service manual:
FORK OIL
• Use fork oil whose viscosity rating meets specifications
below.
Fork oil type : Fork oil # 10
Capacity (each leg) : 382 ml (12.9/13.5 US/Imp oz)
• Hold the front fork vertically and adjust the fork oil level
with the special tool.
NOTE:
When adjusting oil level, remove the fork springs and compress
the inner tube fully.
09943-74111 : Fork oil level gauge
Oil level: 99 mm (3.9 in)
The 3.9" is the empty space from the top of the tube to the top surface of the oil. (Some after market springs suggest as much as 4.5" space.)
Update, purchased the following:
- New GS500 Haynes Manual
- 1l of 15w Fork Oil
- Dot 4 brake fluid
- A suspension linkage (used, was £5 + £5 P&P on eBay, mine is f%&ked)
- Some 7/8 22mm bar ends in black
- New OEM front brake lever for £3 :D
- Fork oil and dust seal set
- 14t front sprocket
- New Handlebar grips
- New Mirrors (3rd pair iv'e bought, but im sticking with these! Others were shaZam!.)
http://www.ebay.co.uk/itm/261005547873?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
I was hoping id done spending, but when i removed the front fork suspension, I lost a few bits and have no idea which bits fell out. So I really could do with purchasing some new/used forks. Cheapest I can find is £50 each side :cry:
I took your advice on the fork oil and went for 15w. Thanks :thumb:
Got a little more done yesterday, paint stripped the clipons and their raisers ... mmm bubbly
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0606.jpg)
Hoisted the frame up :D
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0627.jpg)
And applied 2 coats of primer, first being etch
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0631.jpg)
(http://i718.photobucket.com/albums/ww189/Byard/GS500/DSC_0632.jpg)
Slowly getting there!
Just awating delivery of 12x cans of 600ml brake cleaner I ordered over a week ago, still not arrived and its holding me back now :nono:
Primed frame, and bought an ultrasonic cleaner :D , will post pics later
Decided to give the battery tray an electrolasis bath tonight :icon_lol: