GStwin.com GS500 Message Forum

Hi, here is my build so far of my GS500, i am copying this across from another forum but will start keeping this updated now i finally have managed to activate my account  :D

Here is the story of my GS500, where better to start than a little intro.

I have been brough up around suzukis and kawasakis by my Dad and ever since then i've loved both but never had a kawasaki!

So far i've had; 2x RG250's, GSXR750 slabside, TS250x, TS100er, RMX250, RM250 and my 2 GS500's.

I bought the GS as my NCB are tied up on my RM250 and i wanted someting cheap to run, cheap to insure with no NCB and the GS fit the bill perfectly.

I bought this 97 GS500 in october 2012, it's pretty much standard, with the addtion of the nexxus exhaust, hagon rear shock, 2008 front end and a screen. It had been looked after well and i rode it all through this winter which has taken its toll on it, poor thing!

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_0218_zps1da3b47c.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_0218_zps1da3b47c.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_0217_zpsaedb9537.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_0217_zpsaedb9537.jpg.html)

Then when browsing on ebay for GS bits i came across this 06 GS as spares as it has been sat 2-3 years and has no key, bars, stand or headlight. I won the bid and went to london to pick it up.

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3215_zpsb0896d4a.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3215_zpsb0896d4a.jpg.html)

I left it for a couple of weeks until my car had its MOT and now that its got 12months on it I dont need the GS to fall back on so its full speed ahead with the project.

Here are my plans for it:
R1 Solo Seat
Custom exhaust
Custom subframe
Some sort of dominator or projector lights
Custom undertray
Different speedo (vapor etc...)
Different front end (RGV)
GSXR rear wheel
K&N lunchbox
DIY timing advance
-1t front sprocket
Rejet with  3jet carbs
Remove PAIR system
Powdercoated frame
Custom paint bodywork

I got in the garage last night and tonight and here is my progress so far
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3508_zpsd4a17c77.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3508_zpsd4a17c77.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3518_zpsabaac512.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3518_zpsabaac512.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3519_zps3a4624e1.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3519_zps3a4624e1.jpg.html)
oh dear typical output shaft bodge!
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3521_zps4ff7d4ff.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3521_zps4ff7d4ff.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3532_zps9273fb2f.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3532_zps9273fb2f.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3533_zps8c6e3c9b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3533_zps8c6e3c9b.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3534_zps29983201.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3534_zps29983201.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3535_zps2d628551.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3535_zps2d628551.jpg.html)
Engine with the knackerd output shaft and seized exhaust bolt
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3536_zps8db00b1f.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3536_zps8db00b1f.jpg.html)
Ruined shock lingage bearing
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3537_zpsb99ec380.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3537_zpsb99ec380.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3539_zps394a78f1.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3539_zps394a78f1.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3547_zpsad2332b5.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3547_zpsad2332b5.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3558_zps27beba16.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3558_zps27beba16.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3559_zpsf33784ee.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3559_zpsf33784ee.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3578_zps52f53f0f.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3578_zps52f53f0f.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3581_zpsb14e7321.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3581_zpsb14e7321.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3585_zps5a786307.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3585_zps5a786307.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3598_zps7540564c.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3598_zps7540564c.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3599_zpsb9ca5d2d.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3599_zpsb9ca5d2d.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3610_zps78d96c9b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3610_zps78d96c9b.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3622_zps40d51c80.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3622_zps40d51c80.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3627_zps66888e0e.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3627_zps66888e0e.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3632_zps3b362455.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3632_zps3b362455.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3634_zps1a4ae141.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3634_zps1a4ae141.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3635_zps8ca47065.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3635_zps8ca47065.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3641_zpsfb2aca94.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3641_zpsfb2aca94.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3639_zps415e6b3e.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3639_zps415e6b3e.jpg.html)

Sorry for so many photos i just didnt want to bore you with words! I need to fab up somethin to go from the rear seat bracket to the subframe as i dont think its substantial enough at the moment. I also plan on using the GS seat lock mechanism so once i modify the seat to fit (its too long) i can sort the mechanism, then get the frame off for shotblasting and powdercoating


So i spent the spare hour i had this afternoon grinding down all the excess weld/brackets that i don't need, i managed to do the pillion foot peg mounts, a fair bit on my welds, cut the airbox brackets off and ground a few more areas flat. Only got another hour or twos worth of grinding at the back then il brace the subframe, test fit all the bits that live under the seat incase i need to make any more brackets up before the frame goes for shotblast and powder.

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3663_zps8dcb4e50.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3663_zps8dcb4e50.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3665_zps7a6bb116.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3665_zps7a6bb116.jpg.html)

So i haven't had a lot of time to spend on the bike (been working 11 hour days :( ) but sat out in the garden yesterday for several hours polishing my downpipes which are in a very bad way!!
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3694_zpsb27a58eb.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3694_zpsb27a58eb.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3703_zpsd2adbbbb.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3703_zpsd2adbbbb.jpg.html)
still got a long way to go
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3703_zpsd2adbbbb.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3703_zpsd2adbbbb.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3704_zpse0e6ad2b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3704_zpse0e6ad2b.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3706_zps0dd4d8f8.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3706_zps0dd4d8f8.jpg.html)

When it got dark i went in the garage and tried unseizing the rear brake caliper from the torque arm for woodie, unfortunaltey it didnt go well!
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3692_zps409d8b85.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3692_zps409d8b85.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3693_zps7441016d.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3693_zps7441016d.jpg.html)
So it looks like i'm going to have to rebuild and use the only other one i have.

I started stripping the 97 bike and found the shock linkage has a very rusty bearing, by the look of it i only need 1 or maybe 2 new spacers, going to change all the bearings in the shock linkage and swingarm.
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3713_zps45491434.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3713_zps45491434.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3714_zps51c62bc8.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3714_zps51c62bc8.jpg.html)

General stripping photos
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3722_zps038eef06.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3722_zps038eef06.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3723_zps9debfe16.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3723_zps9debfe16.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3727_zps68845ebd.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3727_zps68845ebd.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3730_zps5aebeb17.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3730_zps5aebeb17.jpg.html)

As i expected, the front engine bolt was seized in nice and tight, so out came WD40 and the blow torch.
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3732_zps27f8c40a.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3732_zps27f8c40a.jpg.html)
after a lot of faffing around i managed to get the bolt moving inside the engine case but instead of coming out the other side it started pulling the engine towards me. it turns out the spacer is completely welded to the bolt.
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3734_zpsb8e6ac15.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3734_zpsb8e6ac15.jpg.html)
So i cut through the spacer and bolt so i could remove it from the engine casing, then i knocked the bolt out the otherside. I plan on using stainless threaded bar but need 2 spacers as i have 0 now.
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3735_zpsf7ac0f5c.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3735_zpsf7ac0f5c.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3737_zps2038bd74.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3737_zps2038bd74.jpg.html)

Then i took the engine out
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3738_zps6c658eef.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3738_zps6c658eef.jpg.html)

and forgot to take a picture! The sprocket has a little play on the output shaft, it looks in pretty good nick (28k miles) but i can see how it will start wearing now rocking back and forth every gear change.
Pointless photo i was just happy its not welded on!
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3740_zps41f82b48.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3740_zps41f82b48.jpg.html)

Thats all so far, i have started cleaning a few bits from the 97 bike and boxing them up so they are ready to go on the 06 frame when the time is right! Very time consuming but worth doing now so the rebuild should be quicker and more enjoyable. The frame should be going for blast and powder this week sometime, I need to test fit the front end to see if i need to cut the steering lock off and then finish off the subframe.

Does anyone know a way to get the engine in the frame without scratching it? It's a tight squeeze when its in one piece!

So I didnt spend long in the garage yesterday but i did test fit my front end and had a look at the exhaust, need to get an adapter made by longlife to go from the downpipe to the link pipe but thats one of the last things i can do as the bike will have to be built so i can get it the perfect angle.

Heres a teaser of the exhaust
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3772_zps6f7582cd.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3772_zps6f7582cd.jpg.html)

Heres some pics of the front end test fit, to the eagle eye'd people out there the wheel is the wrong way round yet the tyre is heading in the right direction, what a pain as i will have to get the tyre swapped around :!

If you read this Woodie, did you have to get custom length braided lines because the splitter joins to the bottom yoke and you raised the bottom yoke up by several inches makeing the lower brake lines too short?

Pics
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3776_zpsf909f8b0.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3776_zpsf909f8b0.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3777_zps0c4bb42b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3777_zps0c4bb42b.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3778_zps877026da.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3778_zps877026da.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3779_zps221c89b8.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3779_zps221c89b8.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3780_zpsa2e45580.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3780_zpsa2e45580.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3786_zps72ac9afc.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3786_zps72ac9afc.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3787_zps8474e145.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3787_zps8474e145.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3791_zpsc1449d64.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3791_zpsc1449d64.jpg.html)

I cleaned the engine up (only quickly) with WD40 and some rags and it has come up way better (looks better in pics) but i'm unsure whether to paint it or not?
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_3799_zps6728c792.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_3799_zps6728c792.jpg.html)

Lastly i'm sure you've seen my post in the main forum but here is the rip off prices Suzuki want for the suspension and swingarm bearings.
(http://i145.photobucket.com/albums/r217/mjj4/GS500/C0641D39-BF5C-42BE-B5E0-B4EC9CBACA6D-9763-000007D57FB8F8F0_zps77443665.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/C0641D39-BF5C-42BE-B5E0-B4EC9CBACA6D-9763-000007D57FB8F8F0_zps77443665.jpg.html)

I think the only one i have to buy from suzuki is the 17x24x26 as it isn't a standard size but luckily this is the cheapest one at £12.11 :-) the others have been ordered from a local bearing supplier and one needs to come from wemoto £8~

Think the bikes going to be painted black to start with then possibly white afterwards

Quote from: gl0ckage;129812Found the spacers, they are in a bad way could do with cleaning.
If you want them pm me address just pay postage.

Thanks for the offer mate but Tom on here managed to sort me out (Cheers tom!) I would keep hold of them as they seem to be one of the most common items to get cut up!

So i got in the garage yesterday and set about making the R1 seat fit between the seat unit and tank, as you can see from the photos below its a fair few inches too long. So after chopping the plastic, foam and recovering it, i have a seat finally. I'm not 100% happy with the seat cover because i used the original cover and it has a few creases as you will see below, but it's not my highest priority at the moment, i can come back to the seat cover later on. Let the pictures speak most of it:







I set about fitting the GS seat mechanism to the seat and subframe




Fitted the seat rubbers into the frame



As you can see those ugly bolts that bolt the seat unit to the subframe will be replaced with stainless steel dome head allen bolts, they still might not be to everyones taste but i like the idea of not having to go underneath to unbolt the seat unit, i could have gotten away without using them at all as the seat holds it down nice and tight but thats a bit cowboy as it will be loose when the seats off! Tempted to see how much it will cost to get the seat recovered professionally but it only creases when i put it on the bike due to the angle of the seat unit so don't want to pay and have the same thing happen.

Behind the scenes i have also pressed the bandit and GS stems out and pressed the GS stem into the bandit bottom yoke, pressed all the bearings out of the swingarm and shock linkage. My only jobs now are to sleeve the top front welds i did  on the subframe to strengthen them as they are the most imporant 2 welds, brace the rear of the subframe where the two parts meet, oh and drill out the two bolts on the swingarm that hold the little mud deflector thing as they both sheared. Then the frame and swingarm and a few other bits are ready for shot blasting and powdercoating yay!

So my highest priority is getting the frame ready so it can go for shotblasting and powdercoating along with a few other bits, so i decided to sort the last bits out, i made the battery tray fit up behind the seat as thats the only place it will fit and be out of site, just need a sealed battery now (pain as mine is only 2 months old!). I also braced the top of the subframe where i modified it, which i'm far happier with now ( i will still load test it somehow ).

List of jobs to do on the frame before its ready:

Brace the rear of the subaframe where the lower and upper meet
Fit the bracket for the starter solenoid
Make sure there are no other brackets required
Knock the lower headstock race out somehow
Make sure i can mount the numberplate somehow (hopefully on an undertray)
Send for shotblasting and powdercoating yay!

Oh i also got round to drilling out the two bolts i snapped in the swingarm and cleaning the threads up with a tap.

Here are some pics of the battery tray and bracing plates i fitted

Wanted the battery about here (only real option)

Modified and fitted battery tray

Yes i need a sealed battery

Finally getting some better welds







Thats all for this evening, i'm busy tomorrow so hopefully get the frame finished on thursday evening so i can drop it off on friday :balloon

So thats where im upto at the moment, my deadline to have it on the road is the end of this month and then do any finishing touches as i go and over this winter. Sorry if thats a bit old chunk to read hopes its not too boring!!

Good luck with the build. If I remember, my brother and I put the motor on a small table and then lifted the bare frame over it. That seemed to be easier.http://imageshack.us/a/img248/1151/photo0590f.jpg

Good luck with the build. If I remember, my brother and I put the motor on a small table and then lifted the bare frame over it. That seemed to be easier.http://imageshack.us/a/img248/1151/photo0590f.jpg
Sorry for the double post

Quote from: bryan88 on May 08, 2013, 02:41:55 AM
Good luck with the build. If I remember, my brother and I put the motor on a small table and then lifted the bare frame over it. That seemed to be easier.http://imageshack.us/a/img248/1151/photo0590f.jpg
Sorry for the double post

Thanks, thats a great idea i will definitely try that, frame is a fair bit lighter than the engine!

This is a really awesome build. Keep the pictures coming! The more the merrier. Good luck with what you have left to do, excited to see the outcome.

found a vapor trail tech unit for 50 us. might work for your situation. its small but usable. thought about getting it for the battlepig.  ( my goped gtr40 ) didnt have cash to spare. but 50 versus 115 seemed like a good deal :)

What did you use to polish up your exhaust header pipes? I'm assuming more than just spit and elbow grease...

 sub'd!  :thumb:

Awesome project, progress and photos!!! Props mang!

Quote from: jacob92icu on May 08, 2013, 09:09:05 PM
This is a really awesome build. Keep the pictures coming! The more the merrier. Good luck with what you have left to do, excited to see the outcome.

Thanks, me too haha

Quote from: yamahonkawazuki on May 09, 2013, 12:05:53 AM
found a vapor trail tech unit for 50 us. might work for your situation. its small but usable. thought about getting it for the battlepig.  ( my goped gtr40 ) didnt have cash to spare. but 50 versus 115 seemed like a good deal :)

Ah thats so cheap, i have a trail tech vapor on my RM250 so could try it for size/looks on the gs, theyre £100ish over here so i expect thats about $160 at the moment.

Quote from: jdoorn14 on May 09, 2013, 04:49:24 AM
What did you use to polish up your exhaust header pipes? I'm assuming more than just spit and elbow grease...

I started off with 00 grade (very fine) wire wool and autosol which worked on the best parts of it but took ages, then i used 600 grit paper (dry) by hand and with a black and decker mouse sander which worked way better and the paper didnt leave any scratches that the wire wool wouldnt get out. Then i got lazy and got out the polishing wheels that go onto my drill and haven't finished using the stiffest wheel with the hardest compound yet, only trouble is the hard to reach areas are going to be a pain!

Quote from: cbrfxr67 on May 09, 2013, 07:38:40 AM
sub'd!  :thumb:

Thanks  :D

Quote from: steezin_and_wheezin on May 09, 2013, 08:19:15 AM
Awesome project, progress and photos!!! Props mang!

Cheers dude  :thumb:

If you are going to mount your battery in that manner I would suggest you buy a sealed battery cause thats quite a risky angle! Looks freaking awesome though. Are you going to buy extended battery cables or what?

Yes better welding.  Glad you addressed that.

My GS has its battery on its side and it isn't sealed.  I thought the same thing when I got from po but decided to watch and see.  So far no problems jacob92icu, been about a year now I think,...

Well than carry on! Haha

that trailtech has a tach, speedo and temp

Quote from: jacob92icu on May 09, 2013, 09:15:42 PM
If you are going to mount your battery in that manner I would suggest you buy a sealed battery cause thats quite a risky angle! Looks freaking awesome though. Are you going to buy extended battery cables or what?

Yeah i was planning on getting a motobatt sealed battery for it, shame as this battery is just over a month old! I should only need an extended live as i think the earth may reach but i mounted the starter solenoid far enough down the frame that the rest of the loom should be unaffected. I will probably just make my own battery leads if they need extending.

Quote from: john on May 09, 2013, 11:25:40 PM
Yes better welding.  Glad you addressed that.

Haha yeah i'm no pro welder! i'm still on my first small disposable bottle of gas and thats apparently 6 minutes of welding so i'm happy with how im progressing.

Quote from: cbrfxr67 on May 10, 2013, 07:40:30 AM
My GS has its battery on its side and it isn't sealed.  I thought the same thing when I got from po but decided to watch and see.  So far no problems jacob92icu, been about a year now I think,...

Cheers i will give it a try as it is and keep something underneath it to catch any spillages incase it doesnt like it!

Quote from: yamahonkawazuki on May 11, 2013, 01:57:44 PM
that trailtech has a tach, speedo and temp

Yeah it also has lap times, ride time, accumilated ride time, max rpm/speed, shift lights, temp lights, digital and bar graph tacho, air temp, water temp. They're a great piece of kit

So not much of an update photo wise but the frame has gone for powdercoating along with the swingarm, torque arm, foot peg mounts, side stand and shock linkage. Going to be around a 2 week wait though as they are chocca :(

Going out in the garage now to start getting as much of the other bits ready that i can for when the frame returns  :thumb:

So I havent got a lot done as the frame, swingarm, sidestand, torque arm, suspension linkage and footpeg mounts are in for shotblasting and powdercoating and will not be ready for 2 weeks (end of the month basically) which im absolutely gutted about :(

Means i need to get as much of the bits ready as possible so that i can just bolt everything on and have minimal work to do when the frame is back, although I find it hard to work without the frame as i don't have much motivation to clean up bits etc...

I cleaned up the front caliper pistons, fitted the front headlights back onto the front end, fitted new mini indicators, fitted the rear wheel bearings, knocked out the rear cush bearing and seal and painted it but its come out a horrible matt black which doesnt match the wheel so going to get some satin black and re do it.

I also sanded the mudguard briefly but it needs some filler so going to pick up some P38 filler now.

I ordered some 2001~ carbs and switchgear so i dont have to run a throttle position sensor or any of that pair system with all those vacuum diaphrams etc... these look a lot simpler which = cleaner set up.

On my front calipers (bandit) one side had no metal backing plates on the pads and one side had 2 metal plates? Am i missing 2 or are you supposed to have 1 on each side?

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4128_zps987eac9e.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4128_zps987eac9e.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4138_zpsa9084296.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4138_zpsa9084296.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4140_zps280af774.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4140_zps280af774.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4131_zps4a09bfe1.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4131_zps4a09bfe1.jpg.html)
(Will probably paint the disc silver, it came white)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4132_zpse8e50aee.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4132_zpse8e50aee.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4141_zps9c2b6f71.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4141_zps9c2b6f71.jpg.html)
These metal plates
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4142_zps3f5c306c.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4142_zps3f5c306c.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4147_zps6d321ccf.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4147_zps6d321ccf.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4148_zps55bbd7be.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4148_zps55bbd7be.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4149_zpse0bbc7a4.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4149_zpse0bbc7a4.jpg.html)

Quote from: jacob92icu on May 10, 2013, 10:29:50 PM
Well than carry on! Haha

Maybe so. But id still consider getting hands on a sealed battery. ( gel or agm)

Sweet build man. Keep it up!

Guess what, I got my frame back finally!

During the build i will be using one set of bolts from one GS and then i will zinc plate the other set and swap them over, i wanted to install the zinc plated bolts but i'm on a tight deadline and it can wait so ignore any rusty fastners.

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4321_zps1d9d50f6.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4321_zps1d9d50f6.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4322_zps62e40170.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4322_zps62e40170.jpg.html)

New bearings
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4323_zpsa70aea7a.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4323_zpsa70aea7a.jpg.html)

Laid some new carpet in the cramped build area
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4363_zps296e4605.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4363_zps296e4605.jpg.html)

Swingarm bearings
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4367_zps33f88086.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4367_zps33f88086.jpg.html)

New Braided lines
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4369_zps88bb970f.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4369_zps88bb970f.jpg.html)

Got the frame in the garage and fitted the front end
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4372_zps2beb1173.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4372_zps2beb1173.jpg.html)

Hagon rear shock
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4379_zps958a21e6.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4379_zps958a21e6.jpg.html)

Swingarm and shock linkage installed
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4380_zps606c0435.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4380_zps606c0435.jpg.html)

Up and rolling
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4381_zpseac53b3e.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4381_zpseac53b3e.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4382_zps5b3ab3c2.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4382_zps5b3ab3c2.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4386_zpsb448f490.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4386_zpsb448f490.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4389_zps1f0a29f4.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4389_zps1f0a29f4.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4390_zpsb734967d.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4390_zpsb734967d.jpg.html)

Tank and seat unit on
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4393_zps68c8a4a8.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4393_zps68c8a4a8.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4397_zps361ac6b7.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4397_zps361ac6b7.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4407_zps8b915a46.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4407_zps8b915a46.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4409_zpsbac6e81d.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4409_zpsbac6e81d.jpg.html)

The seat creases seemed to settle on their own, but i still want to re-do it
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4413_zps5c33ce79.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4413_zps5c33ce79.jpg.html)

I wasn't going to put the engine in yesterday evening as i had already done a fair bit and my trolley jack was down my unit but i couldn't resist, so if anyone thinks its hard to get in and out i managed it using just my hands and managed not to damage the frame
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4416_zpsd0990283.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4416_zpsd0990283.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4417_zps5319c54b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4417_zps5319c54b.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4433_zpsbd590514.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4433_zpsbd590514.jpg.html)

New footpegs
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4434_zps3fabfa54.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4434_zps3fabfa54.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4436_zpsa79f1f11.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4436_zpsa79f1f11.jpg.html)

Rolled her outside to have a look with the engine in
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4443_zpse2854618.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4443_zpse2854618.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4446_zps32e9b97a.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4446_zps32e9b97a.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4448_zps83012425.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4448_zps83012425.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4452_zps9fa16df2.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4452_zps9fa16df2.jpg.html)

Finally, i sanded, primed, wet sanded and started the colour coats on the mudguard. I dont have high hopes for it though but we will see!
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4437_zps4b010e73.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4437_zps4b010e73.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4438_zpscc749d7c.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4438_zpscc749d7c.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4439_zps8196e2b7.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4439_zps8196e2b7.jpg.html)

I'm going to start the wiring tomorrow, rear wheel fitting, rear brake system and then start doing something about the exhaust before it goes to longlife for an adaptor. Want my rear light to arrive to i can start on the seat unit.

looks great!

Man it look awesome! I wish I had some moolah to throw around like most people doing projects haha. I have to say however; I dont much care for the handle bars or headlights. I dont know why, but it doesnt matter if I like it or not! Its your bike. Still sweet looking  :thumb:

this is the tt vapor mounted on the goped. unit is a tad smaller than 6" but id say usable and would suffice for a bike installation. can use a thermocouple ( not sure if proper term)  for temp measurement on the engine.
(http://i519.photobucket.com/albums/u360/gstwin/Mobile%20Uploads/0525131602_zpsc7796be3.jpg)

Cheers guys!

Didn't get much time on the GS today, but i managed to sort out the back wheel properly, get the rear brake aligned and bled, put the side stand on and made some progress with the exhaust. I led the wiring loom over the top of the bike to check it runs and it does and sounds great but i cannot install the loom yet as it needs extending for the new battery posistion.

I wet sanded the front mudguard
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4490_zps4f826545.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4490_zps4f826545.jpg.html)

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4491_zps557b3ff0.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4491_zps557b3ff0.jpg.html)

Rear caliper bracket
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4496_zpsbdb90c9b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4496_zpsbdb90c9b.jpg.html)

Rear brake assembly
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4499_zps73c52417.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4499_zps73c52417.jpg.html)

More soon

Quote from: yamahonkawazuki on May 27, 2013, 09:56:48 AM
this is the tt vapor mounted on the goped. unit is a tad smaller than 6" but id say usable and would suffice for a bike installation. can use a thermocouple ( not sure if proper term)  for temp measurement on the engine.
(http://i519.photobucket.com/albums/u360/gstwin/Mobile%20Uploads/0525131602_zpsc7796be3.jpg)

Yeah i have the same unit on my RM250, i've ran it for 4 years now
(http://i145.photobucket.com/albums/r217/mjj4/IMG_4523_zpscdc5e98a.jpg) (http://s145.photobucket.com/user/mjj4/media/IMG_4523_zpscdc5e98a.jpg.html)

So I didnt get chance to update yesterday as i was so busy in the garage, things didn't go as quickly or as well as i wanted! I will try and get a proper update later but to keep you going here is a taster of something i did yesterday

(http://i145.photobucket.com/albums/r217/mjj4/gs500_zps6b7f705c.jpg) (http://s145.photobucket.com/user/mjj4/media/gs500_zps6b7f705c.jpg.html)

Damn, my friend, you've brought that little bike back from the grave. beyond the grave. nice work  :thumb:

GREAT progress so far! Looking really aggressive. Only thing that gets me is the bars. With the aggressive stance of all the parts the raised oem style bars seem out of place. Any plans on different bars, or did you settle on those for comfort factor?

Awesome project mang!!

Quote from: steezin_and_wheezin on May 29, 2013, 08:47:38 AM
GREAT progress so far! Looking really aggressive. Only thing that gets me is the bars. With the aggressive stance of all the parts the raised oem style bars seem out of place. Any plans on different bars, or did you settle on those for comfort factor?

Awesome project mang!!

+5000 thats what I was trying to say earlier haha. If its for comfort though, its understandable.

Just wondering what tires are you running on there? Didnt read the whole post sorry if you already said this lol

awesome work man. wish I could be around to learn!

I appologise for no update in a while but the weekend away with the boys was lovely and i've had a few days without working on the GS now the pressure is off!

So anyway heres some pictures to bring you up to date.

Here is where i sit, the creases are no more and i am happy with the way the trimmed seat now fits
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4615_zps979b78ed.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4615_zps979b78ed.jpg.html)

Took the angle grinder to the ignition so it would stop rubbing on the steering lock
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4617_zps80f0bbd9.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4617_zps80f0bbd9.jpg.html)

Wired the dash up
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4644_zps1c9c5a4b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4644_zps1c9c5a4b.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4645_zps206dd200.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4645_zps206dd200.jpg.html)

New rear light finally turned up!
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4649_zps580dcaf3.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4649_zps580dcaf3.jpg.html)

K&N turned up so fitted that and went for a ride with my Dad on his Harley (yes i know!)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4650_zps03a9eae6.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4650_zps03a9eae6.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4651_zps9ccfeecf.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4651_zps9ccfeecf.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4655_zpsc624592f.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4655_zpsc624592f.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4656_zps5bca61b7.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4656_zps5bca61b7.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4659_zpsdaebaa5c.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4659_zpsdaebaa5c.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4660_zps30efe310.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4660_zps30efe310.jpg.html)

Old plugs are the white and VERY lean ones, new ones are the tan colour (almost)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4707_zpsb1f8e8c1.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4707_zpsb1f8e8c1.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4703_zps777c7f14.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4703_zps777c7f14.jpg.html)

Rear light fitting
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4710_zpsbcb77b28.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4710_zpsbcb77b28.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4713_zps331315a5.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4713_zps331315a5.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4732_zps17f7e188.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4732_zps17f7e188.jpg.html)

Fitted WHITE (yeah right so much for white!!) dash LEDs
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4739_zps874fb4ba.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4739_zps874fb4ba.jpg.html)

Bit more cutting for rear light
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4745_zps48b7ed0c.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4745_zps48b7ed0c.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4747_zps18bc6e7d.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4747_zps18bc6e7d.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4759_zps65a4819f.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4759_zps65a4819f.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4761_zps588de60b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4761_zps588de60b.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4764_zps7fd4a8eb.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4764_zps7fd4a8eb.jpg.html)

Used CAD to make up an undertray template
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4768_zpsd1f53107.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4768_zpsd1f53107.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4776_zps6c7da926.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4776_zps6c7da926.jpg.html)

Finished painting the mudguard
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4780_zps7bce8822.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4780_zps7bce8822.jpg.html)

Made a steel undertray from the CAD template
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4786_zpsfaa004e5.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4786_zpsfaa004e5.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4787_zps04580c65.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4787_zps04580c65.jpg.html)

Wrapped it in carbon fibre
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4798_zps13bd68b8.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4798_zps13bd68b8.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4799_zps921da177.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4799_zps921da177.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4804_zps1156ed8b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4804_zps1156ed8b.jpg.html)
Wired in the numberplate lights
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4805_zps765d02cf.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4805_zps765d02cf.jpg.html)

Few pics of the bike with mudguard and undertray
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4851_zps1f6941e0.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4851_zps1f6941e0.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4854_zpsf52e62ee.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4854_zpsf52e62ee.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4858_zps99e76f7e.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4858_zps99e76f7e.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4860_zps895fcb20.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4860_zps895fcb20.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4863_zpsadb61f8a.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4863_zpsadb61f8a.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4865_zps6a5f9d7b.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4865_zps6a5f9d7b.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4868_zps1951740f.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4868_zps1951740f.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4870_zps84fca81d.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4870_zps84fca81d.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4873_zps80300ff3.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4873_zps80300ff3.jpg.html)
Much better with a realistic size numberplate
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4874_zps4478fece.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4874_zps4478fece.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4875_zpsab71c831.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4875_zpsab71c831.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_4876_zpsf18e36f9.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_4876_zpsf18e36f9.jpg.html)

Exciting news (for me anyway), the seat unit is going to the bodyshop next to my unit on monday to be painted so by the end of next week i should have a bike in one colour! Then all i have to do is sort the undertray so its complete and final and then enjoy it! :mr green: :bike

Looking killer mang!! Dash and taillight looks great

Quote from: steezin_and_wheezin on June 14, 2013, 05:45:19 AM
Looking killer mang!! Dash and taillight looks great

Cheers man! Should be painted by the end of next week

Looks great! cant wait to see more!!! i'd love to do a solo seat setup on mine some-day but theres a reason i ride 2-up alot, maybe some day!
*edit*
Wow thats looking awesome!!!! did you make a custom exhaust yourself? looks awesome!

Awesom. I would like to show pictures of my motorcycle but am still struggling with protocol.

Wow is all I can say. Very technically savvy you are.  :thumb:

very nice
(http://i3.kym-cdn.com/photos/images/newsfeed/000/208/795/7982%20-%20animated_gif%20tagme%20thumbs_up.gif)

Great work!

amazing stuff, keep it up, cant wait for the finished product

Cheers Guys

The bike is so close to being completed now, just need to swap the mudgaurd brace round to bring the front of the mudguard down to the correct angle, finish polising the stainless downpipes i have and get an adaptor made for them and thats it!

I'll shut up now and let the pictures do the talking

(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5538_zps7c0763a3.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5538_zps7c0763a3.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5542_zpsa88db0cb.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5542_zpsa88db0cb.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5543_zpsa9833968.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5543_zpsa9833968.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5546_zpsdc3ba09e.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5546_zpsdc3ba09e.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5547_zps066b379e.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5547_zps066b379e.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5550_zps9be28af7.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5550_zps9be28af7.jpg.html)

And on the bike
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5593_zps6693bca1.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5593_zps6693bca1.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5597a_zpseccdc1f3.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5597a_zpseccdc1f3.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5599_zps9e50b59a.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5599_zps9e50b59a.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5600_zps97530d3e.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5600_zps97530d3e.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5601_zpsc8e98551.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5601_zpsc8e98551.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5602_zps43e20bdd.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5602_zps43e20bdd.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5603a_zps49202efc.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5603a_zps49202efc.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5605_zps3ae708e5.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5605_zps3ae708e5.jpg.html)
(http://i145.photobucket.com/albums/r217/mjj4/GS500/IMG_5610_zpsbe6abf16.jpg) (http://s145.photobucket.com/user/mjj4/media/GS500/IMG_5610_zpsbe6abf16.jpg.html)

That looks damn good man! Damn good.

Great job.

This was a great build thread, it was both ducational AND inspiring. Win win! Congrats on the killer custom ride!  :cheers:

The new 'Bat-Commuter-Bike' ??  :D :thumb: :thumb: :thumb:

I'll shut up now and let the pictures do the talking
:thumb: i like this.

smoking hot bike too

Freaking nice man! That tail is awesome!! All it needs is some club man bars  ;)

Quote from: jacob92icu on July 18, 2013, 02:26:50 PM
Freaking nice man! That tail is awesome!! All it needs is some club man bars  ;)

Or Superbike bars, much more comfortable for long rides, but thats just my opinion.

Thank you so much for all the kind words guys! I am very happy with it, it handles so much better now, is comfy and just all round better!

I really appreciate your comments, it's nice to know people have been watching my build and i hope some of you have gained something from it!

Worked on cars for 30 years and dabbled in bikes after 1999. Not many people these days who will tackle such a project. Congratulations on your success and a beautiful bike, and that from someone who took a 49 Plymought businessmnas coupe, sectioned and channeled it and put it on a Nissan truck frame with a 240Z engine and transmission.

My hat is off to you Sir.

regards
Mech

Old M, where can I go to see the build thread on THAT??   :confused:

The 49 was done 14 years ago. I have a couple of old pictures of pictures but nothing approaching a build thread. Here is one of the body sitting on the frame and engine in the early rough stages of completion. About 6 inches off the bottom (mostly rust anyway) and the rear wheel whells are 9 inches closer to the rear door gap than the original. Car ended up being about the same length as an early VW bug. The rear end of my 37 Ford 5 window coupe is in the background.

regards
Mech

(http://www.imghst.org/uploads/pzri5yuv4yv9.JPG)

That is one awesome bike. Love the craftsmanship that went into it. Also, i freaking love the exhaust! Congrats on the awesome bike!

Old Mechanic.... We need more pictures!  :D

that exhaust is fantastic. is it a custom made pipe or from another bike?
this bike is b-e-a-utiful, I've just got my gs and been looking for inspiration. and this is it! :thumb:

Just read your thread all the way through....Total transformation from the first page...amazing work. Where in G.B are you?

Quote from: hornet6 on October 22, 2013, 02:21:30 PM
Just read your thread all the way through....Total transformation from the first page...amazing work. Where in G.B are you?

Thanks man, i'm near Reading, you?

Sorry for the delay.....I live near wolverhampton, west midlands.

Are you on gs500e forum? They have a weekend meet in derby each summer and one in Scotland too. Great forum nearly as good as this one  :woohoo:

ever consider a semi cheap engine mod? ( cosmetic only) if engine is silver, put black side covers on, if black, then silver side covers

So I've been riding the GS for a while and just enjoying it, but last week I was riding it home to get my full size numberplate for the MOT and it won't start, when I turn it over by hand on the crank it makes some awful noises and keeps locking up solid. I have a feeling i have GOATS and the centrifugal force kept the magnets in place until i turned the bike off, then they ended up in the gearbox. Either that or they went in the gearbox while i was riding and have been half chewed up and have probably ruined my box!

Bike update coming with a full engine build. Not sure what colour to do the engine and whether I should do any engine modifications while its apart. Any recommendations welcome!!

Magnets in gearbox? :o

Sent from my toilet seat using HTC FartPhone

Just looked up your thread and is really inspiring. I am doing (very very slowly) mine gs500 here in north London. Just wonder where did you have your frame powder coated and how much cost you frame and swingarm?
Sorry to hear about your problems with the engine