Hi all
I am Washington high school student, who is starting a senior project. For this senior project You can do just about anything but i decided to work on my 1992 Suzuki GS 500. Currently my bike is sitting in my garage with its engine in pieces due to an unfortunate valve job accident, including the camshaft journal holder bolt(the bolt is Threaded in the cylinder head.  What I plan to do is repair and reassemble the cylinder head, then replace the carburetors with aftermarket Parts from SUDCO, bore-out the cylinders to 78mm, Install new pistons from WISECO, replace the cams to aftermarket versions, Replace the exhaust to aftermarket exhaust, test drive the bike to see if I have correctly assembled the upgrades, and then test the performance on a dyno to see how much its improved since its stock setup, finally, apply a coat of paint to all the body pieces. Why I am bring this to your attention is because I am in need of a mentor for this project. I am looking for someone who is either a motorcycle technician or someone who is very experienced when it comes to the GS500. I would be paying for all the parts, all you would need to do is answer some of my questions related to my project and meet with me to over see my installation of some of the parts, from now until may. So if you are intrested in helping me please,, please contact me at usernameZPD@gmail.com or 206-455-Three,Eight,Three,Four

Here are some photos http://s824.photobucket.com/user/usernamezpd/slideshow/

So you would like to stop by the West Seattle Bike Cave? 

We have a little experience with GS500's 


And we get together and build one from the frame up in 2 week ends!

that's sounds awesome lets talk more abut this tomorrow

Quote from: usernamezpd on October 31, 2013, 10:28:04 PM
that's sounds awesome lets talk more abut this tomorrow

that's an offer that youd be foolish to pass up . bring a few  Eh?

Quote from: yamahonkawazuki on October 31, 2013, 11:46:26 PM

Quote from: usernamezpd on October 31, 2013, 10:28:04 PM
that's sounds awesome lets talk more abut this tomorrow

that's an offer that youd be foolish to pass up . bring a few  Eh?

High school student: too young for beers but I'm sure he can buy something behind the bleachers......

We're meeting Saturday at the Bike Cave.
I look forward to helping.

Quote from: adidasguy on November 01, 2013, 12:27:27 AM

Quote from: yamahonkawazuki on October 31, 2013, 11:46:26 PM

Quote from: usernamezpd on October 31, 2013, 10:28:04 PM
that's sounds awesome lets talk more abut this tomorrow

that's an offer that youd be foolish to pass up . bring a few  Eh?

High school student: too young for beers but I'm sure he can buy something behind the bleachers......

Fair enough wasn't aware of the age. btw addy when youre able to make it out this way, drinks on me .

I signed the papers. He will get his own work spot in the bike cave for his project. Talked him out of putting on an "F" headlight (they always look fugley) so I've already started "mentoring". He will do a thread/blog on it to document it for his school project. Plan is to upgrade everything - including changing his 1992 to 3 jet carbs and 2006+ wiring.

It will be exciting. Glad I am able to help him learn all about the GS500.

Big thanks to Patrick(adidasguy) for becoming my mentor, I look forward to meeting the rest of the club in the future.

You could not have asked for a better mentor IMO

Quote from: usernamezpd on November 04, 2013, 05:04:55 PM
Big thanks to Patrick(adidasguy) for becoming my mentor, I look forward to meeting the rest of the club in the future.

Glad to help. I know everyone else will offer any help you need. You can have your own spot in the Bike Cave. We need a work day to clean up, move in the lift for you and maybe seal up some holes so we can keep more heat in there this winter.

It will be exciting and interesting - you will get to help build the Husky bike and other projects - to gain knowledge in doing your project. Lean by doing!

One though I had was to do dyno testing with 5 different spark plugs to actually see if they do make a difference. That would be sweet to have that as a part of your project. (I happen to have 5 plugs: stock, iridium, Brisk and just got in 2 new types of performance plugs). You could do tests on fuel mixture and alternate air boxes, too.

Looking forward to your project! And you will be one of the few people with your own key to the Bike Cave!

Not sure what yuo had on your schedule for tomorrow.
I was thinking it could be a fork day. Rebuild your forks with upgraded springs and seals. I've got the springs so no cost other than helping with other projects (as you learn), Change oil and springs in a newer forks for Husky and put together set of forks for Big Rich on the board,
Sound like  reasonable day?
If you have  other plans, let me know. We'll do it.

Quote from: adidasguy on November 04, 2013, 11:34:28 PMOne though I had was to do dyno testing with 5 different spark plugs to actually see if they do make a difference. That would be sweet to have that as a part of your project. (I happen to have 5 plugs: stock, iridium, Brisk and just got in 2 new types of performance plugs). You could do tests on fuel mixture and alternate air boxes, too.

Dyno charts on the same bike with common mods/jetting would be an awesome resource to have.

Things running today. However there is an oil leak next to the left exhaust where the bolt that holds things together runs through the head. We think the o-ring for that bolt (where it goes between the head and the cylinders) is out of place.

Any opinions?

Quote from: adidasguy on November 30, 2013, 11:03:00 PM
Things running today. However there is an oil leak next to the left exhaust where the bolt that holds things together runs through the head. We think the o-ring for that bolt (where it goes between the head and the cylinders) is out of place.

Any opinions?

Maybe I'm mistaken but I seem to recall only the outer four studs having o-rings... have you already torqued the head nuts with a valve adjust or is that still on the to do list?

You are right on that. Just thinking a bit. It has been a long day.
Possibly a defect in the head gasket. Not much else that will cause oil to leak from there.
There is the possibility that in the rush last weekend when it was reassembled, extra o-rings were put in. It was a busy day with lots of people over.
We plan to remove the head next Saturday and take a look.
Any other idea why oil would flow from there?
I wonder if the crush washer on the top is bad and oil leaks down? Or that one bolt/nut didn't get torqued? I hope it cold be that simple.

Oil leak fixed. Just needed to re-torque the head bolts.
Zak rode her/him home Saturday. He still needs a name for his bike.
Carbs have an odd hanging problem. Seems mechanical. As you adjust the idle screw, you can feel a snap at a point as you adjust it out and the idle suddenly drops. Must be mechanical. He's going to pull thecarbs and check for parts binding somewhere.
We did a carb sync.
Baby powdered the motor after fixing it. Maybe a tiny leak from the cam chain tensioner area but no head leak.

Zak - pictures? please?

the rpm still hangs at 4k its probably a vacuum leak somewhere on the boots, photo up date http://s824.photobucket.com/user/usernamezpd/slideshow/

We can look at that after Christmas.
WD-40 didn't show any hint of a leak. We can try again.
Ride him/her a lot and get some miles on it.