Hey guys/gals.  I purchased a 1989 GS500e last year & I'm going to do a complete teardown & rebuild.  I'm open to any kind of help/suggestions from you all.  Some of my goals for the bike are:

1. To be light as possible

2. To be as powerful as possible

3. To combine newer technologies to make an older bike even more fun to ride

I stripped a lot off my bike this winter. Cut the tail, plastics are gone, passenger pegs and seat area. Replaced the gauges and such. Not a whole lot of weight to be saved on an old E model really. I only cut about 15 lbs. Still debating on removing the center stand. For power I would swap the air filter and exhaust, then re-jet the carbs. Not much there either, but it's something. I will probably be swapping exhaust next winter and that will tap out the normal power increase options.

As far as tech...well, I swapped the gauges, and, I suppose you do LED lights all around, change the front end with a newer bike (or just put progressive springs in). Not much tech on this thing to swap really.

http://gstwins.com/gsboard/index.php?topic=63334.0

I think I'm gonna go with the Shorai battery, which will take over 6lb. of weight off alone.  I want to keep the stock look, but improve where i can.  K & S turn signals might me going on front & rear since they are dot approved and much lighter than stock ones.  Going with a K&N filter & full jardine exhaust.  Dynojet jetkit has already been ordered.

I'm debating whether to get the frame/swingarm powdercoated or have them painted.  I think paint might be better option.  Opinions?

i vote powder,...just cause I want to see it! 

Servus,

I vote PAINT 

Painting is fine. Powder coating needs a BIG oven. Powder coating also needs a spotless frame. Paint can go over left over crap.

Eastwood has a Rust Dissolver. Works great to remove rust.

Most of your weight is in decending order:

1. Engine
2. Frame
3. Tank full of gas
4. Forks
5. Rear shock and triple and brakes


Turn signals maybe will save a pound of weight. Same thing you can do with a good pee or poo before you go riding.

Not sure the purpose of stripping off weight. Most weight is frame and engine - that's probably 325 pounds or more of the 400 pound of the bike. maybe you can remove 10 pounds without taking away the look of the bike. To get rid of more weight, you have to start stripping off the pretty parts.

Shori battery, besides weight, just makes sense for better performance.

You could go aluminum rear sprocket to save a pound, but I've personally seen how bad they are and wear out fast.

Yeah, I'm really not counting on much more than a 10-15lb weight reduction.  I'm hoping the jetkit/exhaust/lunchbox combo is gonna satisfy my performance needs.  Gonna go with the Galfer "wave" rotors & steel braided brake lines which should set the bike off.  Supersprox sprocket combo possibly.  Don't think their sprockets are aluminum, but I care more about strength in that area vs. weight.

Powder coating is better IMO. But as Adidas said, painting is easier

I think I'm going to sand what rust I can with my sander, then use the rust disolver.  Hit the frame with some quality primer & then silver paint.  Seems like the best option.  I just think the powdercoat is gonna be pricey, & paint can always be touched-up.

So got some goodies in the past couple of weeks.  They include K&N lunchbox air filter/K&N oil filter/lowering links/NGK plugs/Galfer brake lines/turn signals/Katana 600 rear shock/Stage 1 & 3 jet kit

Oh, & I got the motor out!!  Going to re-paint all of the parts & order rest of parts I need then start putting back together.  Hoping to have bike up & running in about a month.

So, with my limited amount of time, I'm down to the frame & forks.  The wiring harness is in need of a good cleaning also.  So is the all the rest of the bike