OK here I go. I have never done a build thread before but there is always a first time for everything, Right... Like doing a dual sport make-over on a little two banger. Should be fun.
I came up with idea to even venture into the dual sport thing from a push from a friend who just bought and old beater KLR650. :2guns: O0 And well, I couldn't say now to the offer from another friend to buy his 05 GS500F with 8k on it for $1300. And the games begin!
So I jumped on here just to see what these bikes are all about. (I'm and old superbike nut with Hayabusas and ZX14's) A great site this is! I ran into a few threads were this sort of mod had already been done. Thanks to all those guys who have gone before me and posted there mod info on this site and the various related sites. If it were not for your info and attention to details, I wouldn't even attempt this mod/conversion.
I will first start by loading up a few pics of the bike in it's stock form. Bear with me because I need to learn the formalities of GSTwin photo upload protocol. :technical: I will throw up a list of parts that I have slated to use on the mod (please jump in whenever you feel you have a better idea - I reserve the rights to make my own decisions though :bowdown:
Then I will chronicle the process from beginning to end , that is if live thru it.... You can tell I love the wig-digs they make me laugh and we all need more of that in our lives...
See you soon
HERE IS THE PROJECT BIKE:
2005 GS500F Bone Stock!
(http://i680.photobucket.com/albums/vv164/writetodwayne/008_zps49928dab.jpg)
THIS IS WHAT I HOPE TO BUILD!!!!!
(http://i680.photobucket.com/albums/vv164/writetodwayne/074_zps136fbace.jpg)
OK, so I have my homework cut out for me trying to figure out how to upload photos here. Good-GRIEF!!! No way to edit a post either.... off to college I go :cookoo:
EDIT: Ok, it's just me and my inabilities to navigate this site and not the good work of it's designers :kiss3: See, I do kiss and make up :dunno_black:
Just saw the quote button after @BockinBboy pointed it out to me in an unrelated conversation. I also NOTICED! the "Modify" button of which I'm using right now to suck-up to the Moderators!! :bs:
Anyway, I got it! This part that is....
(http://i680.photobucket.com/albums/vv164/writetodwayne/th_008_zps49928dab.jpg)
Here you go! :thumb:
To see how I did it, just click the quote button on this reply.
To edit your previous posts, click the modify button next to the quote button of the message you want to edit.
:cheers:
- Bboy
Dude, u da man! lol...
I just got back on here to see if anyone thru me a lifeline... I took some more pics and wanted to load them up. I have to go see what you did to load that thing.... you must have locked onto the URL that I pulled from photobucket.
Anyway thanks!
OK, so now you've seen ONE MORE GS! :woohoo: Let's try to make thie thread at least interesting for the new modsters... we'll see.
Sign me up. I enjoy a good dual sport conversion as much as the next guy.
(http://i680.photobucket.com/albums/vv164/writetodwayne/008_zps49928dab.jpg)
You mean you couldn't see that little pic Jack?! :icon_lol:
- Bboy
Not without my glasses. :icon_lol:
Even Bettter!!! gsJack :cheers: Thanks to you and Bockinboy. Now I need to figure it out myself.....unless you guys want to bow up all my posted pics??? :bs:
Here is the beginning list of things to expect:
2005 GS500F / KATANA CONVERSION TO DUAL SPORT
BUILD SPECS. PLANS
SUSPENSION EDIT: 3/14/14 Before you run off and buy a bunch of parts, wait until I here from whoever owns the Model Bike that I hope to build. Apparently he has an easier way to do the Front Fork mod, not using the dual disc Katana Forks. For those who just want longer forks without the headache of doing new triple tree and the whole shebang! Just follow along, he will show up from somewhere and let us know what he did...
(Front)
Katana 600 or 750 up to 1987 will work (check on later models IDK)
Katana (96) GSX600F frontend - forks - dual disc brakes also adjustable
Katana ( 96) 600 upper triple and lower Triple
Katana (00) GSX750F Axle (it's longer than the GS)
SealSaver fork seal protectors
Stock fork oil
GS steering stem swap-will done to adapt the Katana 600 front end to the GS
Will need Custom Spacers to take up length on the GS to 600 Steering Stem (hoping for help form a GSTwin member on this
Adjustable Handle bar Clip-ons (because I want handle bars that are not low sport type) Katana clip-on will work
Stock handle bar controls carried over
(Rear)
Suzuki SV650 (yellow spring early model) rear shock-stiffer, more rearend height
Stock GS swing arm and linkages
BRAKES
(Front)
Katana(96) 600 stock dual disc
Katana (93) 600 stock 4 piston calipers x2
5 extra brake rotor bolts - must remove the plastic cover from stock rim if you decide to use it
Katana (93) 600 stock master cylinder & lever
GS brake Lever should work
Carbon Kevlar Pads
(Back)
All stock GS 500F (so far I plan to keep it this way)
WHEELS AND TIRES
(Front)
Stock GS 3.0 inch wheel-is the same as the stock Katana 600/750 up to 1987 front wheel so it matches the front end upgrade
(Rear)
Complete stock rear wheel @ 3.5 inch wide good enough
Stock 39 tooth GS sprocket
Tires
Both Shinko Dual Sport 705's These are a good between sport tire. Not too knobby for mostly street use.
(Size)
120-90-17 Front-up from 110-70-17
140-80-17 Rear-up from 130-70-17
FRONT FENDER
I'm working on which one will fit my off-road look. If you want you can use a stock Katana fender.
*Credit for most of this plan design goes to:
@Dgyver
@ben2go
@some guy who has a lot of custom stuff done with many picks on Flicker
PARTS REUSABLE FROM YOUR GS500
- Front axle spacer
- Nut for front axle
- Speedometer pick-up
- Front wheel
- Right side spacer
- Rotor bolts (5)
BODY / FRAME MODIFICATIONS
Engine Guards – SW-Motech crash bars
Custom made Belly Pan......... this will be work
Custom made small saddle-bag holders
Dual Projector beam headlight aftermarket from china
Mini LED spot lights
LED turn signal from and rear that are close to the frame so they won't get snagged
Kickstand – extend the stock one
Hand brush Guards some dirt bike ones I had laying around – see the experiments...
More to come........
"PROJECT 2014 DUALSPORT GS500", PROGRESS SO FAR: 3/14/2014
Fairings are off but I kept the headlight on until I receive my new one in the mail:
(http://i680.photobucket.com/albums/vv164/writetodwayne/031_zps276edc80.jpg)
(http://i680.photobucket.com/albums/vv164/writetodwayne/030_zps70e54df0.jpg)
Found a burned wire. Wondered why the Tach wasn't working?? I spliced and soldered-in new sections of wire and all is working again: Bit of an oil leak to at the valve cover...
(http://i680.photobucket.com/albums/vv164/writetodwayne/026_zpsbf483a4a.jpg)
This hose just fell out. Not sure where it goes on the engine, some sort of drain:
(http://i680.photobucket.com/albums/vv164/writetodwayne/025_zps7cae84cf.jpg)
Can't seem to loose these brackets. They hold the oil cooler lines to the frame; maybe Ill mount some lights at the screw-hole bungs...
(http://i680.photobucket.com/albums/vv164/writetodwayne/028_zps57ffa809.jpg)
Donor mirrors from my old 1979 KZ1000. Almost threw them away, several times! Pack-ratting pays off! :woohoo:
(http://i680.photobucket.com/albums/vv164/writetodwayne/036_zps107bda10.jpg)(http://i680.photobucket.com/albums/vv164/writetodwayne/032_zps33991779.jpg)
New (used) SV650 Rear Shock:
(http://i680.photobucket.com/albums/vv164/writetodwayne/033_zpsd36e8a8f.jpg)
Tire Comparison, Stock vs Shinko 705's. BTW, be careful with old tires. I see a lot of cracking in mine though the rubber has much treads left:
(http://i680.photobucket.com/albums/vv164/writetodwayne/034_zpsee0e2015.jpg)
(http://i680.photobucket.com/albums/vv164/writetodwayne/035_zpse70bddb3.jpg)
More to come, no doubt...
On that tube that fell out... You've got three possibilities altogether - however, I'll give the best bet.
The larger of the two shown there should be your airbox drain - NOTE that tube should also have a cap type thing on the end - that cap thing lets gas out if carbs overflow into airbox, but should let not anything back in... so you need to get one on there.
The smaller diameter tube right there should be your tank overflow (looks like the one in question). That connects to the nipple on the underside of the tank next to the tank petcock. You definitely want that on there so gas doesn't overflow over the top of a hot engine...
The other possibility is your battery vent tube... which connects to your battery and directs acid away from your bike if the battery were to 'spill' or overflow for some reason... but I bet the tube in question is actually the tank overflow.
- Bboy
Quote from: BockinBboy on March 14, 2014, 10:22:26 AM
On that tube that fell out... You've got three possibilities altogether - however, I'll give the best bet.
The larger of the two shown there should be your airbox drain - NOTE that tube should also have a cap type thing on the end - that cap thing lets gas out if carbs overflow into airbox, but should let not anything back in... so you need to get one on there.
The smaller diameter tube right there should be your tank overflow (looks like the one in question). That connects to the nipple on the underside of the tank next to the tank petcock. You definitely want that on there so gas doesn't overflow over the top of a hot engine...
The other possibility is your battery vent tube... which connects to your battery and directs acid away from your bike if the battery were to 'spill' or overflow for some reason... but I bet the tube in question is actually the tank overflow.
- Bboy
Bboy, I want to thank you specifically for taking the time to give attention to my project and all my questions. I really appreciate people who have knowledge and are WILLING to share it, as opposed to those who has knowledge and don't care to bother taking the time to help another by SHARING it.
On the tube: I will have to pull the tank to see what's going on with it, sooner rather than later now that you have lit the fire of urgency under my but about gas possibly going onto the engine - if its the fuel overflow tube. I'll post back with which it was.
Right now, I'm in a bit of a pickle with getting some Steering Stem Spacer turned down on a lathe. I had anticipated @dgyver doing them for me, as he offered to do some for a few to those who needed them. Now he says his lathe is broken so I need to find someone with a lathe that is willing to turn the spacer for me - I would pay of course.
ANYBODY KNOW OF SOMEONE WITH A LATHE THAT HAS THE SMARTS TO TURN OUT THESE SPACES???? HELP!!!
These are the spacer that I need(http://i680.photobucket.com/albums/vv164/writetodwayne/ForkspacersKatanatoGS500Forks05_zps6ec07c41.jpg)
This is where the spacer go on the Katana Triple Tree Stem.(http://i680.photobucket.com/albums/vv164/writetodwayne/KatanatoGS500spacerForks206_zpsd09d18db.jpg)
This is everything installed: Katana front end with the spacers all pressed onto a GS500 Steering Stem.(http://i680.photobucket.com/albums/vv164/writetodwayne/KatanatoGS500spacerForksinstalled306_zps87b39dff.jpg)
No problem 1200 ;)
- Bboy
1200, since you havnt posted in about a week, I am going to assume you ran into the same problem I did last week.
The yellow SV650 shock is not, and will never be, a direct bolt on. Even if you drill the lower mounting hole higher, the shock will either hang up on the linkage, or rub the swingarm, or both. These are serious problems.
Some members have welded extensions into the stock dogbones to raise the swingarm back up; I chose to make my own bones. If you are so inclined, I can give you some dimensions.
I am working on a similar project, Im hoping to finish tomorrow. I will upload some pics later.
Also, on redrilling the SV shock, theres a stamping on one side, I think mine was 189, not sure if its a part number or manufacture mark or what, but I drilled right on that 8.
Here is one of the dog bones after paint. I gave myself 2 options for height, one high and one low.
(http://i325.photobucket.com/albums/k387/w201028/IMG_0352_zps20e777ad.jpg)
This is how it looks mounted, with the drilled shock joint visible.
(http://i325.photobucket.com/albums/k387/w201028/IMG_0355_zps03af0d19.jpg)
Note the bare minimum clearance between the shock and swingarm. With stock bones, the arm rode the coil.
(http://i325.photobucket.com/albums/k387/w201028/IMG_0356_zps35156eaa.jpg)
Here is the final product. See the 2x4 under the center stand? I can barely turn the rear wheel without dragging the ground.
(http://i325.photobucket.com/albums/k387/w201028/IMG_0362_zps9388741c.jpg)
Quote from: W201028 on March 28, 2014, 11:45:34 PM
Here is one of the dog bones after paint. I gave myself 2 options for height, one high and one low.
(http://i325.photobucket.com/albums/k387/w201028/IMG_0352_zps20e777ad.jpg)
This is how it looks mounted, with the drilled shock joint visible.
(http://i325.photobucket.com/albums/k387/w201028/IMG_0355_zps03af0d19.jpg)
Note the bare minimum clearance between the shock and swingarm. With stock bones, the arm rode the coil.
(http://i325.photobucket.com/albums/k387/w201028/IMG_0356_zps35156eaa.jpg)
Here is the final product. See the 2x4 under the center stand? I can barely turn the rear wheel without dragging the ground.
(http://i325.photobucket.com/albums/k387/w201028/IMG_0362_zps9388741c.jpg)
You just don't know! :-) I haven't gotten back to the project, just crazy busy with work!!!
Your post is right on time!!! I am getting a bit of a break and heading back to the project; ready to tackle the SV shock. Thank goodness you posted your experience before I got to it.... I am still waiting on a few parts to come in and prepping for doing the
custom bushing fabrication listed in the pics further up this thread.
I got the idea to use the SV shock from a couple of the guys that have done mods on the GS, one is a member here, another on AVrider.
Thanks so much for the specs on the dog bones!!! I can make them or possibly find some on the same dimension online.
Just looking back at you pics: I wish I had more space inside a garage to work on the bike. I'm out in front of the drive and at night forgetaboutit! I have an 86 mustang gt project going in the garage right now.
Let's stay connected. I want to hear more about your build. What frontend are you using?
Although I have not done this particular mod before with an SV650 shock, I was not aware of any issues with the swap. I could see there being a problem if you had shorter than stock dog bones (which would change the angle of the shock, and draw it nearer the swingarm), but not with the stock sized dog bones. All references I see with the SV650 shock swap note that if you don't drill holes (and cut off the excess), you will raise the seat height about two inches - but, otherwise I've never seen anything noted about it hitting the swing arm. The only known 'direct' shock swap that has such minimal clearance is the R6 shock, and even then it doesn't have to be modified. :dunno_black:
:cheers:
- Bboy
SV650 shock > I just ran into that this weekend. I drilled a hole into the bottom and it just
would not clear what i call the knuckle (not sure what the correct name for it is).
I tried for some time, measured the dog bones, they are stock, than looked into my
parts pile and gutted an 1989 swingarm with the cast aluminum knuckle, it's shape allows
to bolt it on and gives enough clearance (the 1/4 to 3/8 you need)
Be prepared to brace the bike up on a 2x4 as the center stand wont lift if high enough
to have one wheel off the ground after / when you put the shock in
Using that cast knuckle all you have to do is drill a hole in the shock mounting taps, about midway from the original hole to the top of the bracket and it will fit in as is (you dont have to
shorten the tabs).
So no modification to your frame other than the knuckle.
here is what i mean:
left side: newer still 'knuckle' off a 93
right side: old style 'knuckle' off a 89
(http://www.illenium.de/GSTWINS/IMG-20140329-00487.jpg)
I was trying to say that its only a direct bolt on if you want the aprox. two extra inches of height without changing dogbones. If you want same as stock height - you have to drill new holes AND cut off the excess where the old holes are, because that will interfere with the knuckle as illenium pointed out... I thought that part was well known... if you had different info, it mislead you. SV650 shock is used most often used in builds that need/want extra height. But regardless of this, it should not hit the swingarm unless there is something else different in there such as shorter dogbones.
Edit:
Here is wiki link. Shows you need to drill new holes and cut off excess.
http://wiki.gstwins.com/index.php?n=Upgrades.RearShock#sv650
- Bboy
actually, the problem was not just the swing arm but knuckle. the design of the
welded knuckle didnt fit with the mounting tap of the shock even after drilling the hole.
the old cast knuckle is slightly longer and gave enough clearance.
To clarfiy, even after drilling the hole, the bike is now about 2 inches higher. I did not
cut off the excess either as it doesn't interfer with anything on the old style knuckle
The bike I'm working on is a 93, I didnt do this on my 2001 nor 2004 so I can't comment
what the situation is on newer bikes. It all came down to about 3/8 of an inch
Cheers
Ah yes, I can see that is confusing - Drill and cut is still about 2 two inches higher than stock.
:cheers:
- Bboy
Quote from: illenium on March 31, 2014, 01:27:08 PM
actually, the problem was not just the swing arm but knuckle. the design of the
welded knuckle didnt fit with the mounting tap of the shock even after drilling the hole.
the old cast knuckle is slightly longer and gave enough clearance.
To clarfiy, even after drilling the hole, the bike is now about 2 inches higher. I did not
cut off the excess either as it doesn't interfer with anything on the old style knuckle
The bike I'm working on is a 93, I didnt do this on my 2001 nor 2004 so I can't comment
what the situation is on newer bikes. It all came down to about 3/8 of an inch
Cheers
The plot thickens! I'm a bit confused: does he Sv650 fit with just the drill and cut or is it like you say and "@W" above states that there id clearance issues with all year GS's? I'm beginning to think that maybe there is a subtle difference in the Rear suspension of the GS within this year model parameter. Maybe the later models won't have this clearance issue (I Hope Not) I have the o5.
I have the sv shock already, but I have attempted the mod yet because I want to do the front at the same time and I'm waiting on the bushing fabrication job that a friend and I are going to attempt; necessary to get the 750 Katana front to mate to the GS goose-neck. Haven't used that word in a while :icon_lol: since my bicycle destruction days...
What front setup are you running?
the 93 i'm working on has the same ' knuckle' as the 2004 in my garage. The dog bones are the
exact same length. I would presume that will have the same clearance issue that I had on the 93. People
have done it before, maybe they didnt have stock dog bones though?
I just rebuilt the forks and used progressive springs, i weigh 200-215 depending on the month, i always
bottom'd out on the stock springs, quite annoying. Still modding the GS, will be able to comment on how
the new setup rides in about 2 weeks :cheers:
Quote from: illenium on April 01, 2014, 06:28:39 PM
the 93 i'm working on has the same ' knuckle' as the 2004 in my garage. The dog bones are the
exact same length. I would presume that will have the same clearance issue that I had on the 93. People
have done it before, maybe they didnt have stock dog bones though?
I just rebuilt the forks and used progressive springs, i weigh 200-215 depending on the month, i always
bottom'd out on the stock springs, quite annoying. Still modding the GS, will be able to comment on how
the new setup rides in about 2 weeks :cheers:
Man that bottoming-out must have been a biachi! I'm 170 and it is driving me crazy! I normally ride a Busa or my ZZR1200 Kaw, so this bike is a big leap in the other direction of speed and suspension build design. The progressive spring mod was on my list for a while but I redirected to the Katana front to get the ground clearance and to balance the bike to the rear shock mod.
Those stupid bushings have slowed the train!!!! :icon_twisted:
I'm still fighting to get use to the GS rpm on the highway. 60mph for 5k rpm is hard to get used to, especially when you are coming from a machine that at 70mph is pulling around 3500rpm.
I'm still riding the GS right now, getting to know it, so I'm reluctant to pull it apart. I know that it will be down for a bit afterwards. The weather here in South Florida is BEAUTIFUL!!!!! Full sunny days every day, and around 79 - 82 topping out the day, so I want to ride as much as I can now.
I'm torn between pulling it apart now or waiting because around the end of May, the skies open up down here and it rains almost every day. On top of that the mosquitos are out for blood then, literally!
When I get started, I guess I'll just lean into the rear shock mod with what I have and see what I come up with. I'll post my discoveries and adventures when I'm done.
tell me about it I usually ride a supermoto with tons of travel way :icon_rolleyes:
the gs bikes aren't the most powerful, they are heavy as hunk of lead, lack suspension
travel and sure as heck can drive you crazy, but you know what... I love these bikes :)
So if the progressive spring makes the front end issue go away, I'm a happy camper. the rear
was really only for the extra 2 inches of height and because it was cheap :)
I'd love to live in Florida about 5 months of the year :thumb:
Quote from: illenium on April 02, 2014, 08:45:07 PM
tell me about it I usually ride a supermoto with tons of travel way :icon_rolleyes:
the gs bikes aren't the most powerful, they are heavy as hunk of lead, lack suspension
travel and sure as heck can drive you crazy, but you know what... I love these bikes :)
So if the progressive spring makes the front end issue go away, I'm a happy camper. the rear
was really only for the extra 2 inches of height and because it was cheap :)
I'd love to live in Florida about 5 months of the year :thumb:
You'd actually love to live in South Floirda, most of the years, for about 7 months :whisper: Topping out here in April at about 83 :wink:
I can see where you are going with the suspension height on your gs coming from supermoto. Let me know how your springs work out.
I'm beginning to get used to this little GS. The gas mileage is crazy good. I've been using it to do quick errands.
I'll keep working at it and see what I come up with in the end.
BTW, I just picked up a cool set of Military Surplus saddle bags, canvas outer and leather lined...awesome! Now I have to work on a mounting location; it shouldn't be too hard because the bags were designed to be bicycle mail delivery bags so they come with hooks and strap loops to secure them.
1200: sorry not to post back for so long, I spent all last week putting my real dirtbike back together.
As far as specs for the dogbones, I only drilled the "tall" hole (the one you see used in the pictures) about .03" longer than the stock hole spacing. A little change in the length makes a dramatic effect at the swingarm. I really didnt understand how the linkage affected the bike until I got into this little project, but if you put your bike on center, unbolt just the bottom dog bone mounts, and lift the swingarm, you can see just how far the swingarm can move before any big change is seen at the bones.
The second hole I drilled is about .50 on center from the first hole, just enough to give me .25" of steel between the holes. I say about on all these dimensions because the stock bones are stamped steel, and mine were pretty worn on the inside from rubbing the bushings. I mostly measured with calipers and ballparked the numbers to be nice and even.
I used a 31/64 drill, which is a little larger than what I believe the stock hole was; measuring the stock bolt I think was 12mm, but the holes were most certainly stamped with some clearance.
I didnt mount it up using the lower holes yet, I only mocked it up to see how low it would be. I would say about 2.5" lower than than the tall holes. So, I cant say for certain that there wouldnt be clearance issues with the wheel and the fender. I wanted to keep it extremely high for offroad ability, but give myself a second option (or give the next owner an option). However, the SV shock is extremely stiff, and I doubt any issues would arise.
If you have done any real riding with the stock shock, you will be amazed at how stiff the SV spring is. I am about 250lbs on a good day, and the rear hardly moves when I sit down. Its stiff without being pogo-sticky. That being said, you would be safe to use a center-to-center additional distance of .125" without worry of hitting anything, you just wont have the maximum available lift.
If you notice how I cut them, I didnt relieve the upper portion of the dogbones, because there is no need other than weight savings, which is negligible. The bottom however, must be cut back to the stock shape atleast by the swingarm. Look at the stock ones near where they mount to the swingarm and you will understand. For this, after I drilled the holes, I simply lined up the stock bones on the holes in my new bones, and traced the profile.
Hopefully that is enough info to get you started. I used 1018 mild steel, because it is fairly easy to work with and cheap as dirt. I dont know what stock was, but as it was .25" thick and stamped, it couldnt have been too hard of steel.
And in response to your question of front end, I am running stock forks with Sonic Springs 1kg/mm I believe. I put these in not long after I got the bike due to constant bottoming. For the current offroad setup, I just dropped the forks down as far as they can (safely) go into the top triple clamps. It bought about .80" or so lift at the front. It does feel a little low yet in the front, so I may consider a different front end, depending on if I decide to sell the bike or not. I am curious to see how your front end works out, it might help me decide what to do with mine.
Quote from: W201028 on April 07, 2014, 09:57:20 PM
1200: sorry not to post back for so long, I spent all last week putting my real dirtbike back together.
As far as specs for the dogbones, I only drilled the "tall" hole (the one you see used in the pictures) about .03" longer than the stock hole spacing. A little change in the length makes a dramatic effect at the swingarm. I really didnt understand how the linkage affected the bike until I got into this little project, but if you put your bike on center, unbolt just the bottom dog bone mounts, and lift the swingarm, you can see just how far the swingarm can move before any big change is seen at the bones.
The second hole I drilled is about .50 on center from the first hole, just enough to give me .25" of steel between the holes. I say about on all these dimensions because the stock bones are stamped steel, and mine were pretty worn on the inside from rubbing the bushings. I mostly measured with calipers and ballparked the numbers to be nice and even.
I used a 31/64 drill, which is a little larger than what I believe the stock hole was; measuring the stock bolt I think was 12mm, but the holes were most certainly stamped with some clearance.
I didnt mount it up using the lower holes yet, I only mocked it up to see how low it would be. I would say about 2.5" lower than than the tall holes. So, I cant say for certain that there wouldnt be clearance issues with the wheel and the fender. I wanted to keep it extremely high for offroad ability, but give myself a second option (or give the next owner an option). However, the SV shock is extremely stiff, and I doubt any issues would arise.
If you have done any real riding with the stock shock, you will be amazed at how stiff the SV spring is. I am about 250lbs on a good day, and the rear hardly moves when I sit down. Its stiff without being pogo-sticky. That being said, you would be safe to use a center-to-center additional distance of .125" without worry of hitting anything, you just wont have the maximum available lift.
If you notice how I cut them, I didnt relieve the upper portion of the dogbones, because there is no need other than weight savings, which is negligible. The bottom however, must be cut back to the stock shape atleast by the swingarm. Look at the stock ones near where they mount to the swingarm and you will understand. For this, after I drilled the holes, I simply lined up the stock bones on the holes in my new bones, and traced the profile.
Hopefully that is enough info to get you started. I used 1018 mild steel, because it is fairly easy to work with and cheap as dirt. I dont know what stock was, but as it was .25" thick and stamped, it couldnt have been too hard of steel.
And in response to your question of front end, I am running stock forks with Sonic Springs 1kg/mm I believe. I put these in not long after I got the bike due to constant bottoming. For the current offroad setup, I just dropped the forks down as far as they can (safely) go into the top triple clamps. It bought about .80" or so lift at the front. It does feel a little low yet in the front, so I may consider a different front end, depending on if I decide to sell the bike or not. I am curious to see how your front end works out, it might help me decide what to do with mine.
Hey, I know how working on two or three project can make posting on progress a J O B. My friend that is helping me with the steering bushings has been tied up with work too, so that is taking a bit longer than I expected. going riding this weekend on the big bikes so that will push me further off. I haven't been out on them in a while working on everything and I have an itch to ride.
I'll keep you posted on how the frontend works out. If you look at the pics of the guys who have accomplished it, it seems to be well worth it. We'll see....
Thanks friend.
Dwayne
What kind of big bikes are we talking about? Big adventures or big sportbikes?
Quote from: W201028 on April 11, 2014, 10:25:38 PM
What kind of big bikes are we talking about? Big adventures or big sportbikes?
Big Sportbikes.... ZZR1200 and a 40th Anniversary Busa... I just picked up an 05 GSXR 750 as a project bike as well. I went for a long ride this weekend on the Kaw and I'll be Darned if I didn't find myself missing the little GS! I've been knocking about on the little thing and have grown quite fond of it.... :D
Yea its funny how that works isnt it? I bought a Speed Triple 1050 last year, parked my gs for most of the season and enjoyed the power of the triple. Then this year the first thing I get out is the gs, and this little adventure project really invigorated my love for the bike again. The only thing I really like more about the triumph is the highway roll on power, and the looks ofcourse. But darting around on the gs is just as fun as any sportbike.
Kinda tough doing these Build Threads when you have a full plate of other jobs...
Anyway, here's a little update on the build. I have the crash bars on now and I must say, they look pretty cool. I would get these even if I weren't doing dual sport. They fit well and are a very easy mod - just need a floor jack and your torque wrench.
Still working my way to getting the bushings made so I can go all out....uG!
(http://i680.photobucket.com/albums/vv164/writetodwayne/0013_zpsca0ec2ee.jpg)
(http://i680.photobucket.com/albums/vv164/writetodwayne/0023_zps35741600.jpg)
(http://i680.photobucket.com/albums/vv164/writetodwayne/0033_zpsb6b834b7.jpg)
(http://i680.photobucket.com/albums/vv164/writetodwayne/0043_zps96cf80b4.jpg)
Where did you get those crash bars? I think I need some!
Quote from: neatus on April 23, 2014, 01:26:03 PM
Where did you get those crash bars? I think I need some!
Al Mitchell
Accessories International
13343 SW 131 ST
Miami, FL 33186 US
Phone: 888-725-3679
International: 786-242-5400
E-Mail: info@accessoryinternational.com
Se Habla Español
Code
Product
Quantity
Total
TTLSBL-05-339-100 Sw-Motech Crashbars / Engine Guards for GS500 E/F 1 $174.99
Oh hell yeah, those are the best looking crash bars Ive ever seen for the GS. Hows the fit with the fairings on, or did you already toss them? I would punch holes in mine and fit the bars, if I dont sell the bike soon!
Quote from: W201028 on May 01, 2014, 09:00:06 PM
Oh hell yeah, those are the best looking crash bars Ive ever seen for the GS. Hows the fit with the fairings on, or did you already toss them? I would punch holes in mine and fit the bars, if I dont sell the bike soon!
Why sell the bike? I think I'll keep mine around like having a bicycle in the corner, you just jump on it whenever you need to make a short excursion. Like I mentioned, I am not so happy on the highway with this gs but I can say: It has saved me a lot of money on gas! I would have to un-wrap the big bikes, get one all set up, and then worry about where I parked once I reached my destination, less someone steels it. With the gs, who cares! I park anywhere.... I'll keep mine for a long time.
The Crash bars
are cool. I think they make the bike look a bit on the rough-neck side... a start. I'm not sure about working them into the fairing fit, but give it a try - you won't have to worry about scratching them....unless you do it while punching holes to put them in....wait, is that an oxymoron statement :nono:???? Have fun with it and lnk how it goes.
Yes I am with you on the no worries GS, I think I paid around 5k dollars for it brand new, although it is surprising how many non-bikers call it a GSXR. I guess people who dont ride them, dont steal them either!
As far as selling it, I total around 10 machines between street bikes and dirtbikes and atv/atcs, and I am out of space. Aside from my previously mentioned Triumph S3, I also have a KTM 300 that is street legal, and is fully race ready. The GS fills a gap between the two that almost isnt desirable anymore. Its a slow sport bike, or a heavy dirtbike, and since I have machines at either end of the gap that are better, I hardly ride it. I thought lifting it up would make it better offroad, but in even light mud, it pushes bad in the corners. Ive almost dropped it a few times riding very slow through my trails.
So at the end of the day, it didnt turn out to be the long distance dirtbike that I had hoped for. I dont ride my KTM very far to offroad, I usually trailer it. If youve ever ridden a 2-stroke on the road, you know why. I was hoping I could ride the GS say around 60 miles, go offroad, and then come home with fuel to spare and not vibrated to death. But its just not good enough offroad to satisfy me.
I am planning on putting it on craigslist in the next week or so, its the best time of the year to sell in PA.
Quote from: W201028 on May 03, 2014, 06:05:08 PM
Yes I am with you on the no worries GS, I think I paid around 5k dollars for it brand new, although it is surprising how many non-bikers call it a GSXR. I guess people who dont ride them, dont steal them either!
As far as selling it, I total around 10 machines between street bikes and dirtbikes and atv/atcs, and I am out of space. Aside from my previously mentioned Triumph S3, I also have a KTM 300 that is street legal, and is fully race ready. The GS fills a gap between the two that almost isnt desirable anymore. Its a slow sport bike, or a heavy dirtbike, and since I have machines at either end of the gap that are better, I hardly ride it. I thought lifting it up would make it better offroad, but in even light mud, it pushes bad in the corners. Ive almost dropped it a few times riding very slow through my trails.
So at the end of the day, it didnt turn out to be the long distance dirtbike that I had hoped for. I dont ride my KTM very far to off-road, I usually trailer it. If you've ever ridden a 2-stroke on the road, you know why. I was hoping I could ride the GS say around 60 miles, go off-road, and then come home with fuel to spare and not vibrated to death. But its just not good enough off-road to satisfy me.
I am planning on putting it on craigslist in the next week or so, its the best time of the year to sell in PA.
I truly understand what you mean. With a stable like yours, it would be difficult to hold on to the gs. I just happened to get my in pretty near perfect condition for $1300. I couldn't pass up what has turned out to be a deal. Now in the dual sport capacity, the verdict is still out. I think it will still suit the bill for my off-road expectations - a bit of gravel riding and light mud crossings. Once I get it up of the ground a bit I will see. Hey, good luck with the sell of your gs. You're right, this is the best time of the year to sell, up there that is, we are opposite seasons here in SoFla.
Hope to be in contact in the future. :)
A little suggestion, relocate the horn. I relocated mine to the oil cooler mount, keeps it from getting snagged on things in the garage or in your case the woods :dunno_black:
Quote from: robfriedenberger on May 09, 2014, 04:50:52 AM
A little suggestion, relocate the horn. I relocated mine to the oil cooler mount, keeps it from getting snagged on things in the garage or in your case the woods :dunno_black:
Thanks for that advice on the horn relocate. I have been looking at it every time I get on the bike, thinking of that same scenario where it gets yanked off somewhere off road... Being that this was the Fairing model I believe that location for the horn was viable for the OM.
Sorry that I don't have any progress to post. It turns out that my son has borrowed the GS for a few weeks to get to a class, so I don't get to touch the thing until he gets home after nine. He's about done so I can get back at it soon.
Any suggestions that I get from you guys to make this a better dual sport I will no doubt add to my list of mods at that time....that's the good thing about NOT rushing into a complete mod project and doing everything on your mind right away; often you get great ideas of things to do from other members and then you have time to do everything once and for all... No Re-do's!
Keep the ideas comin, I'll be the test pig... :icon_eek:
Quote from: 1200 on March 16, 2014, 06:55:18 AM
Quote from: BockinBboy on March 14, 2014, 10:22:26 AM
On that tube that fell out... You've got three possibilities altogether - however, I'll give the best bet.
The larger of the two shown there should be your airbox drain - NOTE that tube should also have a cap type thing on the end - that cap thing lets gas out if carbs overflow into airbox, but should let not anything back in... so you need to get one on there.
The smaller diameter tube right there should be your tank overflow (looks like the one in question). That connects to the nipple on the underside of the tank next to the tank petcock. You definitely want that on there so gas doesn't overflow over the top of a hot engine...
The other possibility is your battery vent tube... which connects to your battery and directs acid away from your bike if the battery were to 'spill' or overflow for some reason... but I bet the tube in question is actually the tank overflow.
- Bboy
Bboy, I want to thank you specifically for taking the time to give attention to my project and all my questions. I really appreciate people who have knowledge and are WILLING to share it, as opposed to those who has knowledge and don't care to bother taking the time to help another by SHARING it.
On the tube: I will have to pull the tank to see what's going on with it, sooner rather than later now that you have lit the fire of urgency under my but about gas possibly going onto the engine - if its the fuel overflow tube. I'll post back with which it was.
Right now, I'm in a bit of a pickle with getting some Steering Stem Spacer turned down on a lathe. I had anticipated @dgyver doing them for me, as he offered to do some for a few to those who needed them. Now he says his lathe is broken so I need to find someone with a lathe that is willing to turn the spacer for me - I would pay of course.
ANYBODY KNOW OF SOMEONE WITH A LATHE THAT HAS THE SMARTS TO TURN OUT THESE SPACES???? HELP!!!
These are the spacer that I need
(http://i680.photobucket.com/albums/vv164/writetodwayne/ForkspacersKatanatoGS500Forks05_zps6ec07c41.jpg)
This is where the spacer go on the Katana Triple Tree Stem.
(http://i680.photobucket.com/albums/vv164/writetodwayne/KatanatoGS500spacerForks206_zpsd09d18db.jpg)
This is everything installed: Katana front end with the spacers all pressed onto a GS500 Steering Stem.
(http://i680.photobucket.com/albums/vv164/writetodwayne/KatanatoGS500spacerForksinstalled306_zps87b39dff.jpg)
So you dont have to do so much work you can just press out the katana stem from the lower triple and press in the gs one..easy peasy lemon squeezy. Oh and pick up some new bearing from allballs while your at it..