So I recently picked up my winter project, this terribly neglected 1991 GS500. Here are some pics:









I receicved the bike mostly assembled as you see. I have the good ol' box o' parts to go with it though. I've been going through the box, but thats an uphill battle... I removed the tank and seat to start, the carbs are off and awaiting a good cleaning there. I know I'm missing the airbox, and a lot of misc. hardware. I love doing projects like this, but figuring out where to start is always tough. Any suggestions?

At least it's cousin (the lawnmower) will keep it company in the garage while you're not working in it.

lol

It also has the beer fridge and toolbox to talk to...

I've got a factory air box (including filter with 3,000 miles on it) that I'd send to you if you pay shipping.  Its off of my 05 GS500F...so I'd assume it would fit though I'm not positive.

Projects are so fun.  I can't wait until I have a garage again!

-Turd.

Sweet! I'll let you know soon, I just want to check compatability. And thanks for the offer!!

Take it all apart! Clean up the running gear and the frame. Go from there. Hows the engine?

No problem, I help where I can.

I agree, strip that bad boy down to the frame and go crazy!  You should deffinately do a work log!  Just start a post and update with progress and pictures!  We don't have any of those around here and I love love love to see a project go from begining to end!

Good luck!

-Turd.

Oh...my....

Awesome, I have always bought bikes that dont run and fix them, alot cheaper if you can get a good deal, and way funner because you get to "revived" the bike.  Looks like a fun build, alot like my first bike, 1980 honda cb900, same condition from looks.  Good luck!

If you want it to be a decent bike, you should probally tear the whole thing down, blast and paint the frame, clean up and refinish your parts as required, etc, etc.

But before spending all that time you should make sure the engine works, or at least has the potential to work. I'd start by cleaning your electrical connections, epecially the ignition pickup, coils, new plugs etc to see if you can get spark. Once you have spark, see if you can get decent compression, the thumb on the plug holes method would be fine, if it pops off while cranking the engine (if it cranks) you have decent compression.

Once you have compression and spark, go ahead and strip the sucker down, you'd just to hate to spend all that time and money on the thing if the engine is shot.

Have fun and keep us updated 

The base paint for Krylon Anodized spray paint matches the frame pretty closely.  It should be available in any hardware store.  Check out the book How to Get Your Motorcycle Running by Randy Ellis--it gives some good tips about working with long-neglected bikes.

Chilly

Oh this is going to be fun. I'm definatly going to shoot for the work log thing. My wife is already making fun of me for snapping pics everytime I take another piece off. But hey, I need to have plenty of documentation.

The engine has decent compression, but I have yet no idea as to spark. I would hate to sink a lot of time and money in and then have huge engine problems. But if the engine needs rebuilt, then I can go there too I supose. The deal breaker right now is the title. I've got some interesting problems there at the moment, but I'm fairly confident I can work through them.

The plan right now is to strip her down to the frame, and start blasting from there. New finish on the frame, and then take each part as it goes. My only real worry is the electrical system. Mechanical problems I can fix, but electrical logic has eluded me my entire life.

Kinda wish I had a giant exploded diagram of the thing...

Bikebandit.com has some nice diagrams that I've used when trying to see how stuff fits together.  Plus, there's always the Clymer manual.  Definitely keep us up to date with your photo-log!

Chilly

Quote from: RiderX on October 16, 2006, 12:13:48 PM
Kinda wish I had a giant exploded diagram of the thing...

Someone on here has done just that. Search "Electrical diagram".. should come up within a few posts. I think it was starwalt or dgyver, not sure though. Plus, we're always here to answer questions.

Quote from: Turd Ferguson on October 16, 2006, 11:33:26 AM
I've got a factory air box (including filter with 3,000 miles on it) that I'd send to you if you pay shipping.  Its off of my 05 GS500F...so I'd assume it would fit though I'm not positive.

Projects are so fun.  I can't wait until I have a garage again!

-Turd.

Turd, you're such a damn decent guy!

Got it: http://www.gs500e.co.uk/wire.jpg

Quote from: RiderX on October 16, 2006, 12:13:48 PM... My only real worry is the electrical system. Mechanical problems I can fix, but electrical logic has eluded me my entire life....Kinda wish I had a giant exploded diagram of the thing...

You have nothing to worry about when it comes to the electricals. Between John Bates and myself, we should be able to get you where you want.

I am doing the same thing with my 90 project...except it is taking WAY TOO LONG! Between college kids, work, a wife, a house, four cars, (no pets -- Got sie dank!), going to night school myself, a mother-in-law with Alzhiemer's, burying aunts, visiting mom, and other of life's little surprises, I am surprised that the bike is almost ready to add gas, oil and see if it lives.

Take LOTS of photos. Buy a small parts cleaner with the motorized pump. The 5 gallon can of blue mineral spirits at the auto chain will last the project and then some. Gloves, the disposable kind, are also a great idea.

Dive in, the GS is a great project bike. Hardly any chrome to clean up! Enjoy!

Quote from: RiderX on October 16, 2006, 12:13:48 PM

Kinda wish I had a giant exploded diagram of the thing...

Yes! Please download this! This is exactly what I made it for! A PDF of all the parts of the GS500 in exploded view and labeled

http://tussey.dreamhosters.com/pictures/gs500/GS500E_Parts_Index.pdf

This place friggin rocks!!

The elctrical diagram was just what I was looking for, and the exploded diagrams are going to save my ass, Im sure of it!

Thanks so much for the help guys, and Ill be back with more questions, Im certain!