After over a year of brainstorming hair-brained ideas of building bikes, and getting tons of feedback from different people and forums, I have made up my mind with the most feasible, and within my skill-level, build.

Start with a clean titled gs500 frame, any year, whatever is cheaper.

Gut it, clean it, widen the rear of the frame by a fraction and re-weld so I can use the 636 swinger I have (180 rear tire)

Acquire a kx250 motor and running gear (kick start, pipe, carbs), fab up mounts, shoehorn in. May need to build new engine cradle. Will need to line up engine sprocket with new swingarm sprocket. Thinking of 13/50 gearing, 520 chain.

Rewind stator so it can power a headlight and tail light. Not worried about turn signals, I have hands.

Fab up mounts out of 6061 for rearsets. Will trace somebodies rearsets for a template, and modify the frame mounts to match.

After its running around, chop off subframe and make a smaller one to help with weight and get rid of ugly.

I figure, after all is said and done, this is not as ambitious as building a frame from scratch.

It will drop a shaZam! ton of weight. I figure about 10lbs from the Al swinger, lighter 636 rim, lighter gsxr forks and rim, engine will weigh more than half as much as the GS500 lump, no electronics, starter, other misc crap.

It will have about 15hp and 15 tq more than a stock GS500, will weigh (hopefully) close to 100lbs less than a stock gs500e, I can play with engine placement to change the weight distribution (need more research here).

Specs I'm shooting for:

320lbs (Stock gs500 is 400 wet)
55hp, 55tq (stock for 2005 was 39/25)
180/55/17 rear, 120/60/17 front
hp-lbs = 1:5.8 (stock is 1:10.
Estimated 1/4ET is 10.1sec 1/4 mile

Overall, it will have twice the power as a stock GS, twice the TQ, will be lighter, and it is attainable and shouldn't be crazy expensive being everything here is within my abilities.

Sweet! Do it.

Sounds good.

Watch out for:
1. Illegal dumping of gravel
2. Drop bears
3. Spontaneous combustion

Here's your frame. Clean title and if you want it, bid more than me ($229)
http://www.ebay.com/itm/130764462351?ssPageName=STRK:MEBIDX:IT&_trksid=p3984.m1426.l2649

Why rewind a stator? I have a box of them. Actually I have lots of stuff but seem to be out of speedometers in the pile of tachometers.

Keep us posted and as always: include pictures, drawings, sketches, anything to look at that doesn't have words.

Quote from: adidasguy on September 15, 2012, 11:34:26 AM
Sounds good.

Watch out for:
1. Illegal dumping of gravel
2. Drop bears
3. Spontaneous combustion

Here's your frame. Clean title and if you want it, bid more than me ($229)
http://www.ebay.com/itm/130764462351?ssPageName=STRK:MEBIDX:IT&_trksid=p3984.m1426.l2649

Why rewind a stator? I have a box of them. Actually I have lots of stuff but seem to be out of speedometers in the pile of tachometers.

Keep us posted and as always: include pictures, drawings, sketches, anything to look at that doesn't have words.

Will do. we're closing on the house soon, and wedding is end of October. After thats done, and we're caught up on bills, the build begins!

I will include any scrap of information, drawings, pictures, or anything else that may even be of a slight value.

And, rewind the stator so that it'll put out enough juice for a headlight and taillight. I think a LED taillight and LED headlight should be fine, especially with all the streetlights around here.

Adidas, if your ever in FL, and feel like taking it for a spin, feel free to!

Agree with gi joe. Do it! 

Always remember- to double your speed, you'll need to square the horsepower.

Just an old adage i was once told to make sure my sights weren't set on unrealistically lofty goals.

aside from that: I'm subscribed. Where in fl are ya again?

going to be in plant city

Sounds good, painted in silver gun color would be look nice 

well if you find yourself cruising through tallahassee (until december) or jax (pretty much forever) shoot me a PM, we'll get some dranks.

so im on track for the same project except im using a banshee 350 for a motor.  Let me ask you, what are you using the bike for?  and why a kx250? 

single cylinder smaller displacement 2 strokes dont like sustained high rpm aka street riding. 

For kicking around town and being a complete hooligan!

IDK, by the time I can afford the house, I may have a better idea for a powerplant, but it will still be based on a gs500.

Maybe widen frame and shove a oil-boiler in there...