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Main Area => Projects / Builds, Racing and Tech => Topic started by: tunedbybugaj on June 21, 2012, 04:16:58 PM

Title: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 21, 2012, 04:16:58 PM
I am new to this forum so I figured that I'd put up some pictures and information about what I've done with my gs and see what you all think. It is a 2006 Gs500F and I purchased it over two years ago before I got my license. I was only 15 then so it had decent power but you can always have more  ;). All of the mods have been done by me and my dad. Mostly me. Here is the list so far: SV650 rear shock, handmade fender eliminator, led turnsignals and tail light, mirror blockoffs(sometimes), Jardine full exhaust, K&N lunchbox, custom jetting, Ported head(by me and my dad), head is decked .025, custom ground cams by webcams (.340 lift), valve job, 5 degree ignition advance, Puig windsheild, wheel lips stripped of paint, and more to come! The bike runs AMAZING! The cams are still just breaking in so it will be on the dyno next week. We use a dynojet dyno so the numbers are lower than other dynos. We are hoping for 50hp and 36ftlbs of torque. It revs so fast that the tach cant keep up past 7k and when using mirrors you have to make sure they are tight otherwise when the power comes in they fold up  ;). I hope you guys enjoy and any feedback is appreciated. Oh and idk how to post pictures lol
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: gsatterw on June 21, 2012, 04:25:25 PM
pics or it didnt happen.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 21, 2012, 05:00:49 PM
trying to post them. im not having much luck
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: Phil B on June 21, 2012, 05:19:34 PM
shove em on tinypic, facebook, or whereever, and post a link, to start
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 21, 2012, 05:25:38 PM
(http://i1155.photobucket.com/albums/p545/tunedbybugaj/WP_000031.jpg)
heres a pic of the shock
(http://i1155.photobucket.com/albums/p545/tunedbybugaj/WP_000030.jpg)
(http://i1155.photobucket.com/albums/p545/tunedbybugaj/WP_000029.jpg)
fender eliminator and such
(http://i1155.photobucket.com/albums/p545/tunedbybugaj/WP_000028.jpg)
Back end looking pretty sporty
(http://i1155.photobucket.com/albums/p545/tunedbybugaj/WP_000027.jpg)
(http://i1155.photobucket.com/albums/p545/tunedbybugaj/WP_000026.jpg)
rim after the lip stripping
(http://i1155.photobucket.com/albums/p545/tunedbybugaj/WP_000025.jpg)
doesnt look too bad from the front
(http://i1155.photobucket.com/albums/p545/tunedbybugaj/WP_000010.jpg)
handported D shaped exhaust ports

thanks Phil!
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: cbrfxr67 on June 22, 2012, 08:02:18 AM
With a title like that, really interested!  Great pics by the way.  I'd love to see it against an F2 or F3.  What does your pops do?  I'm thinking he's got some good xp under his belt?
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 22, 2012, 09:23:49 AM
Thanks! and yea me too. I think I have alot of 600s in the 1/8 but im not too sure about the 1/4. Alot of people with 600s around where I am are inexperienced riders with either stock or slower than stock bikes but theyre extremely cocky. And if it doesnt beat 600s the way it is now then I have another trick up my sleeve that will help me win for sure ;). and my dad has been working on bikes for over 30 years now. he started the whole tuned by bugaj thing and hes built countless high performance engines. if you wanna see more highly technical and really cool stuff he did then just google "tuned by bugaj" and theres a guy on the R1 forums named Dee who has a really good write up on everything done to his bike. If you love bikes then you will definately want to read that article.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: shonole on June 22, 2012, 11:54:03 AM
Nice looking bike.  But no way it beats up on 600s.  Unless they are really old, really crappy or have poor riders.   :2guns:

Still, props for thinking outside the box!   :thumb:
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 22, 2012, 12:30:28 PM
Hopefully your wrong shonole but I completely understand where your coming from. But if this setup doesnt work then I do have something for it that will make it faster than most 600s. I definately will not mess with daytona 675s though. theyre in a completely different league. Hopefully next week ill have it at the track to get an idea where I am
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: shonole on June 22, 2012, 12:39:46 PM
Hey, me too!  I'd love to see a GS put down some serious power.  I'd be next in line to mod it!   :thumb:
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: cbrfxr67 on June 22, 2012, 01:46:19 PM
"then I do have something for it that will make it faster than most 600s."

Spill it!  Got me really interested now!  C'mon tuned, itching to hear what you have in mind!
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: k.rollin on June 22, 2012, 06:50:55 PM
Forced Induction? Nitrous?

Or something more Spy Hunter, like rockets and caltrops?
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: bucket_chemist on June 22, 2012, 10:26:21 PM
Quote from: k.rollin on June 22, 2012, 06:50:55 PM
Forced Induction? Nitrous?

Or something more Spy Hunter, like rockets and caltrops?

A wee turbo on a GS would be a nifty set up. I've heard of it being done, but never seen it. Does anyone know how much can you bore out the cylinders on a GS?

And you're my favourite poster for today for making reference to my favourite computer game ever.  :thumb:
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: Phil B on June 23, 2012, 01:34:18 PM
Quote from: bucket_chemist on June 22, 2012, 10:26:21 PM
Quote from: k.rollin on June 22, 2012, 06:50:55 PM
And you're my favourite poster for today for making reference to my favourite computer game ever.  :thumb:

He gets bonus points just for saying "caltrops".

caltrops. 

Not as good as "magma" (http://www.lfgcomic.com/page/276), though.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 24, 2012, 06:50:42 AM
Alright heres my plan. It is forced induction but not a standard turbo or nitrous. My dad built a gs with nitrous probably around 10 years ago and he could run up to a 75 shot reliably on the street and he beat most 750s. I went to the Indianapolis dealer expo this year and saw a 200+ horse turbo gs500. Ill have to look through my stuff to get you more info on that but it was used for Bonneville. But anyways the plan for my gs is an electric turbo. Very cheap and fairly simple to put on. It boosts probably only a little over one pound but I am gonna try to add and extra battery and take the turbo up to 24V. 1-2 pounds of boost may not seem like alot but 1 pound of boost is what the most efficient ram air system achieves. but ill have my boost whenever I hit 7/8 throttle. I think its a pretty cool idea, all i have to figure out is the wiring for 24V
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: cbrfxr67 on June 24, 2012, 07:07:42 AM
 :whisper: sounds interesting but what did pop's say 'bout that,.....
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 24, 2012, 07:50:42 AM
He loves the idea and me and him have been trying to figure out a bike to do it on for a while actually. Im gonna wait a little while before i try it though because we have to make sure the motor is good the way it is now
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: comradeiggy on June 24, 2012, 07:59:38 AM
Quote from: tunedbybugaj on June 24, 2012, 06:50:42 AM
Alright heres my plan. It is forced induction but not a standard turbo or nitrous. My dad built a gs with nitrous probably around 10 years ago and he could run up to a 75 shot reliably on the street and he beat most 750s. I went to the Indianapolis dealer expo this year and saw a 200+ horse turbo gs500. Ill have to look through my stuff to get you more info on that but it was used for Bonneville. But anyways the plan for my gs is an electric turbo. Very cheap and fairly simple to put on. It boosts probably only a little over one pound but I am gonna try to add and extra battery and take the turbo up to 24V. 1-2 pounds of boost may not seem like alot but 1 pound of boost is what the most efficient ram air system achieves. but ill have my boost whenever I hit 7/8 throttle. I think its a pretty cool idea, all i have to figure out is the wiring for 24V
Look into an LM2586. It's an IC voltage multiplier.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 24, 2012, 08:59:17 AM
Very cool comradeiggy. Were thinking about just hooking up both batteries in a series and then the blower going to the secondary battery and have switches to change from the blower coming in and running 24v off the smaller battery to just being a parallel and charging the smaller battery after I make a run. We just have to make sure the rest of the bike doesnt see 24v or else were in trouble lol
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: GI_JO_NATHAN on June 24, 2012, 10:06:53 AM
Yeah there's video on here somewhere of a turbo F/I GS from a few years ago.

OP, you had me up until "electric turbo." Then you fell on your face.

Also, Ignition advance doesn't do anything for late model GS's, I think 02 up. They automatically adjust, so after you advance it, it will switch back to normal. And your mirrors were definitely loose, They don't fold in like that on pretty much any bike.

Oh, and by the way, I'm one of the really nice guys around here. So your post has for sure hit a sore spot.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 24, 2012, 10:36:04 AM
You can hate on my electric turbo if you want but its the best bang for your buck if you wanna do any kind of forced induction with keeping it nice and reliable. This isnt my racebike whatsoever. It is just something that I think is cool and extremely fun to ride and show off. Mainly its different and I like that about it. And im not exactly sure how the timing can automatically adjust itself when you slot the rotor. and besides, its advanced anyways because of the cams and the decked head so either way the timing is advanced somewhat. And sorry it hit a sore spot for you, i know alot of people in the bike industry who love what ive done and am doing with my bike.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: cbrfxr67 on June 24, 2012, 11:21:05 AM
That is kind of why I asked what pop's thought about it.  Everything I've seen on electric turbos has been crap.  Well aside from a leaf blower test in Hot Rod magazine, maybe it was Car Craft where they came out with good numbers, as silly as it looked.

I think though if pops is for it and thinks it could work, then he has the xp to test it out.  Also I thought maybe you were talking 'engine swap' as the next level, making a sleeper GS.

Truthfully I'd like to see what you come up with and how the results show if you decide to try the electric turbo idea.  Always easy to talk about something, like it or hate it, but results from DOING it are different.  Rock on!
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on June 24, 2012, 11:29:48 AM
I know exactly where your coming from cbr. Ive heard alot of negative things about them in the car industry but nothing at all about them in the bike industry. To me and my dad it makes sense to do it and like i said its very cool. The turbo will probably not be on for another month or so though because I just got done doing the cams and headwork. Hopefully it will be done before October because thats when I leave for boot camp. And I am also making a race bike that should be very interesting. 1974 Kawasaki S3. 400 triple two stroke. As much as I love my GS I must say that I love two strokes even more. My dad feels the same way and we have built some pretty nasty two strokes. He has probably built hundreds lol
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: cbrfxr67 on July 11, 2012, 12:20:51 PM
then what happened,.....???
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: Shepa on July 11, 2012, 01:11:18 PM
Hm... this should be interesting...
8)




Might even....

Nah... no way I'm gonna lift that gas-tank again.

;D
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on July 11, 2012, 07:45:31 PM
Sorry its been a while since my last post. I was having some issues with the jetting. In 4th gear up it would stumble at 6k. I couldnt really change much for a week because it was in the 100s here. But just tonight I finally got the jetting straight. It has not been on the dyno yet or the strip but the strip is coming up in a few days if all goes well.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: iclrag on July 12, 2012, 09:31:21 AM
you gotta post some video or something!
and remember, pics or it didn't happen
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: mysterious_rider on July 12, 2012, 03:23:17 PM
Quote from: shonole on June 22, 2012, 11:54:03 AM
Nice looking bike.  But no way it beats up on 600s.  Unless they are really old, really crappy or have poor riders.   :2guns:

Still, props for thinking outside the box!   :thumb:


Off the line it's all skill. My gs500 restricted to 33bhp will happily outrun a fully fledged 600 off the line if the guy isn't 100% confident. That's what I love about the gs's they are so easy to use. Just drop that clutch with a bunch of revvs.

Well it'll outrun it up to 45-55mph anyway!!  :D That's good enough for me!
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on July 16, 2012, 10:58:21 AM
mysterious rider: I cant agree more. Most people with 600s, at least around me, can not ride and are not confident but their too cocky to let a 500 beat up on them so I cant wait to line up against one. I will post results, pics, videos, anything I can get.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: iclrag on July 16, 2012, 11:29:39 PM
So, did you go with the turbo?
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on July 24, 2012, 08:35:47 AM
I have not hooked up the turbo yet because we want to put some more miles on it to see how it holds up with the motorwork. Also I have not been able to get it dynoed or take it to the track because the weather here is not good for riding. It has been close to 100 degrees or even more and very windy. Very sorry for no results yet but the first chance I get I will get some numbers and post them for you guys. In the mean time when its been rainy I decided to remove the centerstand. Nice little improvement.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: SAFE-T on July 24, 2012, 11:20:59 AM
Only being able to 'win' up to 55-60mph seems like being great at math...up until grade 6

I see the point you are making, I just don't get why it's relevant.

You can make similar comparisons between small-displacement (500-800cc) motorcycles and cars. The bike will out-accelerate the car up to 90mph or thereabouts, after which the car will pull ahead. 1000cc + performance bikes are a different story, but the question still remains whether a smaller bike is faster than such-and-such. Because it is and it isn't.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: SAFE-T on July 24, 2012, 11:23:04 AM
I think the only 'win' you can honestly claim is to have made a faster GS500, rather than a GS that can beat a 600.
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: cbrfxr67 on July 24, 2012, 12:26:54 PM
Which makes me wonder, how much can the gs take?  How much can you shoehorn into it before the frame or swingarm would succumb and bend??  Thoughts?
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tunedbybugaj on September 03, 2012, 02:12:18 PM
Hi guys I know its been a long time since the last reply but I finally got my gs on the dyno. It was 90 some degrees in the dyno room and it currently needs a back tire. with that said it produced 45 horsepower. On a 70 degree day with a new tire it will reach 50 easy. The thing that is bothering me is I saw a gs500 on youtube with similiar mods to what I have except megacycle cams and his own custom made exhaust and hes claiming 69 horsepower. Something doesnt seem right. Im wondering if my jardine system isnt doing extremely well. Any thoughts?
Title: Re: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: ohgood on September 03, 2012, 04:29:34 PM
Quote from: tunedbybugaj on June 22, 2012, 12:30:28 PM
Hopefully your wrong shonole but I completely understand where your coming from. But if this setup doesnt work then I do have something for it that will make it faster than most 600s. I definately will not mess with daytona 675s though. theyre in a completely different league. Hopefully next week ill have it at the track to get an idea where I am

stay home. you're at the back. wayyyy back.

the gs is a great bike. solid. reliable. forgiving.

racer, it is not.
Title: Re: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: GI_JO_NATHAN on September 06, 2012, 09:56:12 AM
Quote from: ohgood on September 03, 2012, 04:29:34 PM
stay home. you're at the back. wayyyy back.

the gs is a great bike. solid. reliable. forgiving.

racer, it is not.
Nah they do pretty good...against other 500 twins..
Title: Re: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: shonole on September 06, 2012, 11:37:15 AM
Quote from: GI_JO_NATHAN on September 06, 2012, 09:56:12 AM
Quote from: ohgood on September 03, 2012, 04:29:34 PM
stay home. you're at the back. wayyyy back.

the gs is a great bike. solid. reliable. forgiving.

racer, it is not.
Nah they do pretty good...against other 500 twins..

And 250s!
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: tb0lt on September 09, 2012, 09:17:54 PM
Good effort and best of luck to you.  :thumb:

That being said, the port job looks amateurish. If you did it yourself.. not bad. If your 30+ years exp dad did it, I'm sure quite a few here would call BS on the exp part. I did a better job using a dremel and a grinder bit on a 4 banger when I was in high school. No offense.

Also, I'm not sure what 600s you are used to, but a naturally aspirated unassisted GS is not getting ANYWHERE near any decent 600 (based on my personal experiences with the Ninja 650R, ZX6, TT600, R6, Bandit 600, Kat 600, etc) with the mods you listed. Since you didn't mention any displacement increasing mods (and infact mentioned a shaved head, which in a minor way, reduces displacement), I'm gonna have to assume this setup is aiming for high RPM power. You mentioned cams but I didn't see any mentions of springs. The GS has horrible valve float at high RPMs.

The GS is an econo daily rider... a fun, cheap bike. Lot of fun to throw around a track or in the twisties but pretty bad in the straights unless you are up against some bottom dweller kind of bike. The kind of power and high RPM runs needed to beat most 600s will destroy the bottom end, especially the rod bearings (a well knows issue on this bike). Unless you are planning on upgrading to roller bearings instead of the budget minded crap bearings these things come stock with, you might be setting yourself up for disappointment. Just a heads up.... or call it a rude awakening.

Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: Higgins13 on September 17, 2012, 09:39:58 AM
How did you do that undertail?
Title: Re: My gs500 project. Hopefully a 600 killer but still completely streetable
Post by: mabrio on September 19, 2012, 09:03:44 AM


Bike looking good!