Just unmount the seat release key and bring it to a lock smith, it is easier to unhook that one then just get the keys done from there.

I am so sorry for what happened to her. It is a sad day for GS500's. We do not want to see someone like her on that condition. I'm pretty sure it pains you to see her on the condition. Wears here for you if you need anything in restoring her. Keep up the good work

If you are going to part her let me know.. i am looking for a windshield.

I'm thinking about putting a screw-on aftermarket filler cap in and buying just the ignition and seat lock as a set. Can I get an ignition from any year or do I have to stick to parts from one of the earlier ones?

Quote from: Agno on August 11, 2011, 04:12:53 AM
I'm thinking about putting a screw-on aftermarket filler cap in and buying just the ignition and seat lock as a set. Can I get an ignition from any year or do I have to stick to parts from one of the earlier ones?

You can save a little money by just doing the ziptie release method for the seat and just getting the ignition replacement like
http://cgi.ebay.com/ebaymotors/Ignition-Switch-Suzuki-GS500E-GS600F-Katana-1988-1997-/270786772067?pt=Motorcycles_Parts_Accessories&hash=item3f0c263c63

Also invest in a bottle of Rutland's stove polish... think it was adidasguy who told me about it and started using it on all the rusty parts of my bike to reblacken them.. Works wonders for really cheap...

As someone who neglected their GS for about 3 years, here's what I had to do to get my bike running well:

Thorough carb cleaning
New carb intake boots
Forks overhaul (new oil and seals)
New sprockets and chain
New tires
New battery
Replace oil and brake fluid

Electrical system has been fine. Other than tires it wasn't that expensive, either. I say try and get this running again.

Replaced the chain and sprockets yesterday with no real issues. Guess I was expecting to have a complication or two. Nothing to speak of. Feels nice to see the bike getting cleaned up and sporting new parts.

I was also expecting the Filler cap to give me issues. Thin screw driver into the key hole and it turned first try. Lucky me.
Cleaning the tank out seems like it will be a chore though. Not sure how i'm going to do this yet. I'm seeing a lot of threads about it. Quite a bit of rust came out today when I rinsed it with water so I think something on the drastic side is needed. Doesn't seem to be leaking though.

Keep the progress reports coming; if you've never tried Evapo-Rust, let Google be your guide...

I'm waiting for some parts to come in and decided that the seat needed some love. Picked up a yard of new vinyl at the fabric store and pulled the staples out of the old vinyl.

Once the vinyl was off I decided that this was the perfect time for some small customization. I have never liked the naughty place protector at the front of the seat. So I cut it off with a band saw.




And then I reshaped the front with a Dremel




I have always liked the sculpted seats and thought it might look cool on the GS. So I used the scrap foam from the naughty place guard and added a "speed hump".
\


I already started to cover it in the new vinyl. The bump looks a lot more subtle under the seat cover. Ill post pics after a run to the hardware store for more staples.

Very nice mod, man I think I have thought of everything ... well I like to flatter myself ... but of course this one I might as well not even try, never thought of it, but now that you have, I want to do it.
Cool.
Buddha.

Well thanks Buddha!

Just finished. Its not perfect but it turned out pretty good.

that looks pretty cool, any photos of it on the bike?

getting ready to modify my seat a bit as well. i'm going to be shaving the passenger area down thinner to allow my passenger seat cover to sit flush with my tail fairing. i'll be taking a lot more foam off than you had to, but did ya pick up any tips/tricks on shaving the foam down?

You could do a better job of covering it IMHO ... get the stretchy vinyl and heat it with hair dryer and put it on. That looks good ... good material but your cover job is a bit loose ... looks like its loose.
Cool.
Buddha.

QuoteYou could do a better job of covering it IMHO ... get the stretchy vinyl and heat it with hair dryer and put it on. That looks good ... good material but your cover job is a bit loose ... looks like its loose.

I could have stretched it 10% tighter with 50% more effort but my sore hands had other plans.



Here is a pic of the seat mounted as requested. The bike is still pretty rough but you get the idea.



And a closer shot from another angle.

Quotedid ya pick up any tips/tricks on shaving the foam down?

I didn't have much shaving to do so I really don't have much advice. I used one of those small cylindrical sandpaper fittings with my Dremel. Seemed pretty straight forward. Just slow and steady.

I have 64oz of Evapo-rust churning around in my tank at the moment. A bottle of Kreem is on stand by. Wish me luck.

Great..... I just recovered my seat like 2 months ago and now I want to cut off that front tab.... Looks slick....

I'm glad that Evapo-rust is re-usable because my tank flash rusted before I could even get it dry after rinsing it with water. Any advice on getting the tank dried out more quickly? I was thinking about some alcohol or possibly acetone.

read somewhere earlier today(i think it was on wiki) that a hair dryer wasn't cutting it. the guy used a shop vac and just pumped in LOTS of room temp air

Thanks to Steezin^^^ I finally had the parts compiled to re-key the bike(with spares no less!). Now I know why the ignition came still connected to the triple. That thing is riveted in-place. So for the first time I got to disassemble the majority of the front of a bike. Was kinda cool. I would post a pic but I'm at work and it would just look like the steering head threw up anyway.

The rusty old battery box is currently removed and sitting in a de-rusting bath.

Now just waiting on my Carb jets and the valve adjustment kit and I'll be ready for start up.

is that a Triumph Speed Four I spot?  I would rather be rolling than wrenching!