My first GS street bike creation

dgyver · February 15, 2007, 07:48:36 PM

I have finally completed my first GS500 street bike. Well, completed until I decide to modify something else. I do have plans for a few changes but they are only cosmetic.

It has taken about 1.5 years to build this bike and well over 200 hours of my labor. It is tough to find time when working 2 jobs/7 days a week and going to school at night.

I bought the motor a couple of years ago for $75. It had spun a rod bearing and was taken completely apart in multiple boxes. It was interesting putting it back together without taking it apart. Luckily all the parts were there. Oddly the motor and frame came from the same guy. Plus, they are both from '97.

I have roughly $1500 in parts invested, no labor included. At least I know the condition of every part on the bike. My ideas have changed from when I first started as I acquired different parts. Originally I was planning on making a basic bike but I can never leave anything alone.

My plan as of now is for this to be ridden by my g/f. I do not riding 2-up as she does not either. But first I need to build a bike for myself, which I have already started. I have most everything except for some parts that I have to fabricate. It will be a little more custom.

I have taken a few pictures and will posting more later. Sadly, I did not take many during the rebuild. If there are any particular areas that you would like see or have questions about, please let me know.

dgyver · February 15, 2007, 07:49:27 PM

Below is a summary of the modifications and service which I have done.

Modifications:
Frame & swingarm painted with Eastwood High Gloss Extreme Chassis Black
Swingarm stand spool mounts
Delrin swingarm stand spools/sliders
Steering damper frame mounting boss
Fairing stay mount welded to steering stem
Replaceable steering stop

Stock motor w/ 6000 miles
Lightly polished cylinder head ports
BobB ignition advancer
Aluminum ignition & stator covers (by Chuck81)

2004 gas tank
2005 tail bodywork (decals removed)
Welded mounting tabs from '05 frame
Custom brake light mounting brackets
Custom seat cover (marine grade vinyl)

SV650 gauges (99-02)
SV650 speed sensor (modified for GS axle)
Wire harness modified for direct plug-in

K&N RU-2970 lunchbox air filter
Re-Jetted: 40 Pilots & 142.5 Mains
Shims: 2
Plugged slides
Modified fuel valve with no vacuum (On-Off-Reserve)

SV throttle tube (1/5 turn)
Woodcraft clip-ons

2002 GSXR600 rear shock
Modified upper shock mount w/ adjustable ride height
GSXR lower shock pivot link

89-97 Katana 600/750 forks
Progressive springs
Fork lowers painted with Eastwood Charcoal Gray
89-97 Katana 600/750 front fender
Custom 1/2" aluminum fork brace
89-97 Katana 600/750 triples with GS500 stem
89-97 Katana 600/750 front brake rotors
89-97 Katana 600/750 front brake calipers
EBC HH front brake pads
Goodridge front & rear stainless steel braided brake lines
GSXR front brake master cylinder

GSXR rear brake caliper
Bracket added for mounting caliper under swingarm
EBC rear brake pads
GSXR aluminum brake torque arm
Woodcraft rear brake light pressure sensor switch
Brembo rear brake fluid mini-reservoir

Wheels painted with Eastwood Argent Silver
Bandit 400 rear wheel (17x4")

Metzeler M1 Sportec tires
Front: 110/70-17
Rear: 150/60-17

Custom 10-position adjustable rearsets
GSXR footpegs
GSXR shift pedal
Custom brake pedal (GSXR replaceable)

'04 GSXR passenger mounts & pegs
Mounting tabs welded to sub-frame

Yoshimura slip-on exhaust (from a ZX-11 full system)
Stock exhaust header modified (cut at Y collector)
Repainted header with Rust-Oleum BBQ flat black
Header inlet welds ground to pipe ID

Steel front sprocket: 15 tooth (-1)
Aluminum rear sprocket: 41 tooth (+2)
EK X-Ring 520 chain
SV650 chain guard

Dominator dual 4" headlights
Aztec8 headlight brackets

TL1000R turn signals (shortened with custom mounts)
Aftermarket mirrors

Maintenance:
New wheel valve stems
New steering stem bearings
New front & rear wheel bearings
Lubed swingarm bearings
Lubed rear shock pivot linkage bearings
Lapped valves
New valve stem seals
Replaced crank shaft
Replaced connecting rods
New rod bearings
New crank shaft bearings
Honed cylinders
Motul Brake Fluid
Rotela oil
Rebuilt front and rear calipers
Rebuilt front and rear master cylinders

dgyver · February 15, 2007, 07:51:09 PM

makenzie71 · February 15, 2007, 07:53:50 PM

pretty schnazzy

NiceGuysFinishLast · February 15, 2007, 08:01:36 PM

Damn, looks good. Now when do you start mass producing the custom rearsets?

Seriously, it looks great.. Makes me wish I had the time and money to paint my forks and frame right now.. especially since I've already got the forks apart.. Oh well, sometime in the future.

l3uddha · February 15, 2007, 08:32:17 PM

awesome!

Meighan · February 15, 2007, 08:41:17 PM

Wow D, it looks great!!!!! Makes me miss my old gs!!!

pandy · February 15, 2007, 09:09:36 PM

Gorgeous!!

Turd Ferguson · February 15, 2007, 10:28:35 PM

That's pretty much exactly where I want mine in the next year. Your bike is EVERYTHING a GS should be... I absolutely love it.

Great work, and thanks for sharing all of the pics and information!

-T.

zukiGS500 · February 15, 2007, 11:35:20 PM

Quote from: Meighan on February 15, 2007, 08:41:17 PM
Wow D, it looks great!!!!! Makes me miss my old gs!!!

Sweet zombie jesus, where the hell have you been?

oh yeah, love that gauge cluster

yamahonkawazuki · February 16, 2007, 01:29:50 AM

Quote from: Meighan on February 15, 2007, 08:41:17 PM
Wow D, it looks great!!!!! Makes me miss my old gs!!!

meighan long time no see, welcome back, and damn nice job on the bike man

Alphamazing · February 16, 2007, 03:50:55 AM

...Hot.

Affschnozel · February 16, 2007, 04:25:54 AM

That's a GREAT job! Well done

WREX · February 16, 2007, 06:29:21 AM

fantastic example dgyver.

great choice in stuff and nice attention to detail. thanks for sharing.

Johnny5 · February 16, 2007, 06:49:11 AM

Wow, nice job! Especially knowing that you got it in pieces.. OOPHA.

That looks great!

One day I will get up the nerve (and the money, and the time, and the space - LOL) to buy myself an old bike and do a restore. I've always wanted to be able to tear a bike down and then build it up again.

blue05twin · February 16, 2007, 08:10:30 AM

The bike looks hot, wish I could do work like that.

l3uddha · February 16, 2007, 08:14:04 AM

so what bike are you thinking about next?

scottpA_GS · February 16, 2007, 08:19:30 AM

VERY NICE

Awesome job

dgyver · February 16, 2007, 10:07:40 AM

Thanks everyone for the compliments.

Quote from: l3uddha on February 16, 2007, 08:14:04 AM
so what bike are you thinking about next?

GSXR750 USD front end, RGV banana swingarm w/ Kat wheel, undertail exhaust, race tail, 541 motor from my track bike until I get the GR650 motor w/ the 4-valve head completed. I already have all the parts for the head conversion. In the end it will basically just have a GS tank and a GS frame.

ohgood · February 16, 2007, 10:26:17 AM

that's a boat load o work you've done. i'll take it you're not commuting on this one, given the shape of the tires ?

i'll hopefully be allowed to do a few things to my gs, if/when i get another bike to commute on while this one is in pieces.

good work !

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My first GS street bike creation