89 GS Build-Still Not 100% Complete-UPDATED 4-21-2014

ben2go · July 13, 2011, 06:05:41 PM

Before

VERY FIRST MODIFICATION.COMPLETED THE WEEK AFTER I BROUGHT IT HOME!That seems so long ago now,4 years this past May.99 Yamaha R1 Clear Alternatives tail light.

AFTER

MY BUILD THREAD.
http://gstwins.com/gsboard/index.php?topic=42478.0

Katana 750 Front End Rebuild
http://gstwins.com/gsboard/index.php?topic=40821.0

SV650 Racing Clutch Build
http://gstwins.com/gsboard/index.php?topic=56043.0

How to swap in a larger GS fuel tank on an older bike.
http://gstwins.com/gsboard/index.php?topic=56658.0

04-07 Honda CRF250X Frame Petcock Install
http://gstwins.com/gsboard/index.php?topic=56352.0

89-02 Carbs and their parts description.
http://gstwins.com/gsboard/index.php?topic=56601.0

Fuel Cap Disassembling and cleaning the vent.
http://gstwins.com/gsboard/index.php?topic=41061.0

How I found my fuel tank capacity and reserve range.
http://gstwins.com/gsboard/index.php?topic=56758.0

Cheap starter relay and wiring diagram.Should directly replace the GS relay.
http://gstwins.com/gsboard/index.php?topic=56381.0

GS and Katana cheap disassembly tool and how to.I painted mine.
http://gstwins.com/gsboard/index.php?topic=41239

How To:Sprocket Replacement and Upgrade
http://gstwins.com/gsboard/index.php?topic=57937.0

Ignition Coil Relay Mod
http://gstwins.com/gsboard/index.php?topic=62039.0

My best mod so far has been the Scorpion AGM battery from www.batterystuff.com

If anyone finds one of my other write ups interesting,let me know,and I will add it here.That way we can all keep up with them.

People ask me about my intake,exhaust,and jetting so here it is.

Exhaust= Right side D&D muffler with an adapter to mate a full length GS header.

Intake=K&N Lunch Box (RU-2970) with GS500F intake boots.The 1st gen are discontinued.

Ignition=See relay mod above.New 7mm NAPA spark plug wires and NGK 5000k 45 degree spark plug caps.This made a big difference.

Jetting was a challenge to get a strong pull from idle to redline.
142.5 mains
40 pilots
NO WASHERS
3.25 turns on the mix screw
10mm removed from slide springs= Eliminates the sluggish bottom end from idle to 3500 rpm.Thanks to PeteGS from DoTheTon for being the guinea pig on this one.

Altitudes I ride in vary from 300 feet above sea level to 6600 feet above sea level.

UPDATE

Dgyver and I started on a 569cc engine for my bike.Here are some specs.

80mm Wiesco pistons and sleeves-We are unsure what bike they came from,but they test fit perfectly.
Copper head gasket
polished and ported head
Mega Cycle Cams with adjustable cam gears
36mm GSXR carbs-36mm Flat Slides are on hold until break in is accomplished.

Bottom end and case checked out so all new bearings and seals have been installed.We buttoned up the bottom end this evening.I did swap out a bad output shaft for a used one in good condition.

cbrfxr67 · July 13, 2011, 06:38:02 PM

(lovin' it) F-zantastic!

ben2go · July 14, 2011, 10:40:16 AM

Thanks.I wanted a bike that was modified enough that people familiar with them could tell,but not enough to draw to much unwanted attention.

So far my bike has been accused of being a Ducati,Norton,Triumph,Ural,and some other odd bike that sounds french or italian.

For my next trick,I will finish the seat I been working on,a very special solo tail,and repack the D&D muffler.The muffler is starting to sound bad and the packing is rattling inside the can.I'll do a write up on the muffler repack.I'll post some vids since I finally figured out my GF's camera.

xunedeinx · July 25, 2011, 06:07:51 PM

Well, it isn't french or italian, but it is spanish!!!

ben2go · July 26, 2011, 11:21:31 AM

Quote from: xunedeinx on July 25, 2011, 06:07:51 PM
Well, it isn't french or italian, but it is spanish!!!

What?I don't get it.

xunedeinx · July 26, 2011, 02:26:50 PM

Quote from: ben2go on July 26, 2011, 11:21:31 AM
Quote from: xunedeinx on July 25, 2011, 06:07:51 PM
Well, it isn't french or italian, but it is spanish!!!

What?I don't get it.

Our bikes, even though were designed by the japs, are made in spain.

So, they're Spanish.

ben2go · July 26, 2011, 07:59:43 PM

Quote from: xunedeinx on July 26, 2011, 02:26:50 PM
Quote from: ben2go on July 26, 2011, 11:21:31 AM
Quote from: xunedeinx on July 25, 2011, 06:07:51 PM
Well, it isn't french or italian, but it is spanish!!!

What?I don't get it.

Our bikes, even though were designed by the japs, are made in spain.

So, they're Spanish.

Really?Mine has made in Japan all over it.I knew some where but were all of them?

xunedeinx · July 27, 2011, 03:09:54 AM

IDK, Mine said made in spain on one of the stickers I took off.

crzydood17 · July 27, 2011, 04:08:20 AM

you took off the vin sticker?

mike__R · July 27, 2011, 07:09:03 AM

My 95 said made in Japan.

ben2go · July 27, 2011, 09:57:24 AM

Quote from: crzydood17 on July 27, 2011, 04:08:20 AM
you took off the vin sticker?

Those are completely useless in SC.They made me,strip my bike down,and sand the paint off the head tube so the trooper could read the VIN.The first paragraph of this post explains what I went through to get a title for my bike.It was he77. http://www.dotheton.com/forum/index.php?topic=18622.msg293859#msg293859

xunedeinx · July 27, 2011, 03:16:25 PM

Quote from: ben2go on July 27, 2011, 09:57:24 AM
Quote from: crzydood17 on July 27, 2011, 04:08:20 AM
you took off the vin sticker?

Those are completely useless in SC.They made me,strip my bike down,and sand the paint off the head tube so the trooper could read the VIN.The first paragraph of this post explains what I went through to get a title for my bike.It was he77. http://www.dotheton.com/forum/index.php?topic=18622.msg293859#msg293859

I just read that, I never want to live in SC, ever.

ben2go · July 27, 2011, 05:38:09 PM

Quote from: xunedeinx on July 27, 2011, 03:16:25 PM
Quote from: ben2go on July 27, 2011, 09:57:24 AM
Quote from: crzydood17 on July 27, 2011, 04:08:20 AM
you took off the vin sticker?

Those are completely useless in SC.They made me,strip my bike down,and sand the paint off the head tube so the trooper could read the VIN.The first paragraph of this post explains what I went through to get a title for my bike.It was he77. http://www.dotheton.com/forum/index.php?topic=18622.msg293859#msg293859

I just read that, I never want to live in SC, ever.

If it wasn't for my kids living here,I would move out of the country.Maybe go raid Canada or the Aussies.

GSnoober · August 25, 2011, 02:05:53 AM

Couple of problems with those links; first one here:

http://gstwins.com/gsboard/index.php?topic=56381.msg638106#msg638106

should be changed to:

http://gstwins.com/gsboard/index.php?topic=56381.0

to simplify matters.

Second one here:

GS and Katana cheap disassembly tool and how to.I painted mine.
http://gstwins.com/gsboard/index.php?board=1;action=post2

isn't a complete link at all; can you fix that? It should end with "topic=xxxxx.0", but I'm sure you already know that.

Thanks Ben; I really appreciate the starter relay substitute you found... along with everything else you've written up for us.

ben2go · August 25, 2011, 04:27:01 AM

Quote from: GSnoober on August 25, 2011, 02:05:53 AM
Couple of problems with those links; first one here:

http://gstwins.com/gsboard/index.php?topic=56381.msg638106#msg638106

should be changed to:

http://gstwins.com/gsboard/index.php?topic=56381.0

to simplify matters.

Second one here:

GS and Katana cheap disassembly tool and how to.I painted mine.
http://gstwins.com/gsboard/index.php?board=1;action=post2

isn't a complete link at all; can you fix that? It should end with "topic=xxxxx.0", but I'm sure you already know that.

Thanks Ben; I really appreciate the starter relay substitute you found... along with everything else you've written up for us.

Thanks for the heads up.Links are fixed.

ben2go · March 21, 2012, 06:03:59 PM

UPDATE 3-21-12

I have had issues banging my hands into the tank on my motorcycle lately.My clip ons are great for sport riding but when I am in the really tight slow speed mountain switch backs,I have to go to wide in the curves because of it.So I decided to make some hi rise bars for my clip ons.Here is how things are progressing.

Stock 92 GS500 bars Marked for cutting.

Cutting method of choice.

And cut.

First try,to wide.

Lets scoot those in a smidge and mock up the controls.Better.

Assemble the Targa fairing,make some adjustments, and cap the inside bar ends.Getting there.

That's pretty close.

I am waiting on some parts before I install the front brakes and button everything up.It'll be a few more days, if Ron Ayers will step up and get my parts in that are back ordered.

cbrfxr67 · March 21, 2012, 06:46:59 PM

**Good stuff here! Great pics sir! Ronayers is the slowest ever in the shipping department. A guy I work with actually knows Mr Ayers, and whenever I order something I always hack on him and tell him to tell Ron Ayers his shipping department is the worst.

ben2go · March 21, 2012, 08:03:55 PM

Quote from: cbrfxr67 on March 21, 2012, 06:46:59 PM
**Good stuff here! Great pics sir! Ronayers is the slowest ever in the shipping department. A guy I work with actually knows Mr Ayers, and whenever I order something I always hack on him and tell him to tell Ron Ayers his shipping department is the worst.

Thanks.

Maybe they will get it together one day.This is the first time I have had issues with them being slow.

ben2go · March 21, 2012, 08:08:22 PM

As soon as I posted the statement above,I got an email saying my order has shipped.It's coming from Greenville,NC so it shouldn't take it long to hit my door,Sat maybe Mon.Maybe they are getting it together.It's only been 8 business days since I placed my order.

ben2go · March 26, 2012, 08:32:36 PM

I added the after pics to the first topic of my thread.Still changing as can be seen from the past few post I have made.More to come.

News:

89 GS Build-Still Not 100% Complete-UPDATED 4-21-2014