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Author Topic: 2005 GS500F | Scrambler Project  (Read 35554 times)

Offline Joester41

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2005 GS500F | Scrambler Project
« on: September 10, 2015, 06:26:36 AM »
Hey all, just picked up a 2005 GS500F as a scrambler/tracker project bike. Needs some carb work but runs good otherwise.

What are the K&N lunchbox P/Ns that are compatible with this bike?

What are your recommendations for a header/exhaust replacement/enhancement?

What websites do you recommend for OEM parts (like the headlight assembly and bracket for the GS500E model)?

Do Suzuki dealers still offer part support on 10+ year old bikes?

Thanks in advance for any info on these topics. I'll be posting up pictures of my build as it progresses.
« Last Edit: February 24, 2016, 03:35:14 PM by Joester41 »
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Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline squrit_air

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Re: 2005 GS500F Project
« Reply #1 on: September 11, 2015, 01:14:04 PM »
As far as I know the bike has barely changed over the 20 years they made it. MOST part work across all of the models. Bike bandit had all the parts on mine, and the dealer near me could order all the parts as needed for my bike, an 09gs500f. The light bracket they do have on bike bandit. For the header and exhaust, someone made a system. As far as I know k&n doesn't make a box for it, but other builds have different filter that a OEM replacement.
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Offline akapellen17

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Re: 2005 GS500F Project
« Reply #2 on: September 12, 2015, 04:03:17 PM »
The K&N part number is RU-2970 for the lunchbox filter. I have a delkevic exhaust and I love it! (Much cheaper too) but there is also yoshimura and jardine. If you are already cleaning the carbs then it's pretty easy just to swap the jets to fit the air filter and new exhaust. Either way, the K&N air filter will require a rejet
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2005 Suzuki GS500F
Race Tech Springs | R6 Shock | GSXR Rearsets | Delkevic Carbon | R6 Throttle | Gauge LEDs | Dash Clock | ZG Double Bubble | Chuck81's Fork Brace | Gold D.I.D. Chain | GP Shift | Katana Rear Wheel | Battlax S20 Evo | SV650 Clutch and MC | Braided Brake Lines

Offline Joester41

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Re: 2005 GS500F Project
« Reply #3 on: September 13, 2015, 06:01:09 PM »
Thanks for the info!

Ordered the K&N lunchbox and a stainless delkevic system. Will also be ordering the Mikuni jets tonight 20/65/142.5.

Has anybody had success using universal flasher relays for LED turn signal conversions? I've done this on another bike by just replacing the turn signal relay with a universal LED one, didn't have any problems.

Are there any manufacturers making aluminum throttle tubes that will bolt up without modification? Looking for one without the lip that tucks under the grip.
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Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline squrit_air

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Re: 2005 GS500F Project
« Reply #4 on: September 22, 2015, 10:19:27 AM »
Get some R&G turn signal delays from revzilla, I just hid them in the tail.

Get the 21.5 Ohms
 http://www.revzilla.com/motorcycle/rg-racing-turn-signal-resistors
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Offline akapellen17

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Re: 2005 GS500F Project
« Reply #5 on: September 22, 2015, 02:19:48 PM »
I have an r6 throttle tube on my bike. It takes less of a turn to go to full throttle. There is a thread somewhere on here about it. I'm sure some company makes an aluminum throttle for the r6
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2005 Suzuki GS500F
Race Tech Springs | R6 Shock | GSXR Rearsets | Delkevic Carbon | R6 Throttle | Gauge LEDs | Dash Clock | ZG Double Bubble | Chuck81's Fork Brace | Gold D.I.D. Chain | GP Shift | Katana Rear Wheel | Battlax S20 Evo | SV650 Clutch and MC | Braided Brake Lines

Offline FTL900

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Re: 2005 GS500F Project
« Reply #6 on: October 07, 2015, 12:36:35 PM »
The last flasher I replaced was on a Suzuki Bandit 600 and it was direct plug and play. 
I think the one bike (Superhawk maybe) that wasn't a direct fit required me to change one wire or something... I don't recall, but it was easy. 

I just got a new flasher in the mail yesterday from SuperBriteLED for my Bandit 1200 project. 
I change the flasher on most bikes I work on so I don't have to think about turn signal types anymore, I can just use anything.
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ZRX1100, Bandit 1200S, GS500, EX500

Offline Joester41

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Re: 2005 GS500F Project
« Reply #7 on: November 19, 2015, 03:53:59 PM »
I've been slacking on my build updates,here is what it looked like the day I picked it up...







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Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Joester41

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Re: 2005 GS500F Project
« Reply #8 on: November 19, 2015, 04:00:37 PM »
Some more pics after the fairings and some other parts removed.







Delkevic exhaust fit-up.



Custom skid pan and headlight brackets.




The frame has been chopped, getting the loop welded tomorrow. I will also be bead blasting the skid pan and center headlight mount tomorrow. Stay tuned for more pics.

Not shown in the pics, K&N lunchbox and breather, designing a custom batterybox and some other components yet.
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Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Daeouse

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Re: 2005 GS500F Project
« Reply #9 on: November 19, 2015, 05:16:20 PM »
You sold the fairings and light, didn't you? I'd kill for those. . . I've been scoping the Airstream fairing kit. . .

*shifty glance* Still have it? ;)

Nice work, by the way. Looking forward to seeing where this goes. . .
« Last Edit: November 19, 2015, 05:17:03 PM by Daeouse »
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Offline Joester41

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Re: 2005 GS500F Project
« Reply #10 on: November 19, 2015, 05:34:10 PM »
Quote from: Daeouse on November 19, 2015, 05:16:20 PM
You sold the fairings and light, didn't you? I'd kill for those. . . I've been scoping the Airstream fairing kit. . .

*shifty glance* Still have it? ;)

Nice work, by the way. Looking forward to seeing where this goes. . .

Actually, I still have the fairings and all the hardware...
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Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline UCFjeff

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Re: 2005 GS500F Project
« Reply #11 on: November 19, 2015, 06:49:38 PM »
I like where this is going. What size tires are those?
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Offline Joester41

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Re: 2005 GS500F Project
« Reply #12 on: November 20, 2015, 04:21:58 PM »
Skid pan and center headlight bracket done..




Got the rear loop done and the remaining brackets chopped, just need to clean up the residual welds from the brackets.


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Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Joester41

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Re: 2005 GS500F Project
« Reply #13 on: November 20, 2015, 04:31:40 PM »
Quote from: UCFjeff on November 19, 2015, 06:49:38 PM
I like where this is going. What size tires are those?

120/70-17 front, 130/80-17 rear, continental TKC80s
« Last Edit: November 22, 2015, 03:04:44 PM by Joester41 »
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Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline Daeouse

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Re: 2005 GS500F Project
« Reply #14 on: November 20, 2015, 09:29:15 PM »
Looks excellent so far!  :cool:
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Jon "MotoSquirrel"
2009 Yamaha V-Star 950
My Blog!

Offline mihkels

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Re: 2005 GS500F Project
« Reply #15 on: November 21, 2015, 08:54:00 AM »
Looks great.

Waiting for updates as I'm thinking about a similar build during the winter.
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Offline lucas

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Re: 2005 GS500F Project
« Reply #16 on: November 23, 2015, 01:42:23 AM »
Hi, where did you get the clamps mount your headlight to the front forks?  Did you make them?
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Offline Joester41

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Re: 2005 GS500F Project
« Reply #17 on: November 23, 2015, 01:35:00 PM »
Quote from: lucas on November 23, 2015, 01:42:23 AM
Hi, where did you get the clamps mount your headlight to the front forks?  Did you make them?

Yes, I made them. Designed them in CAD and had a local shop laser cut and form them.

The clamping parts that attach to the fork are from a generic bike master headlight mount.

I also had to make the center mount for the JW Speaker headlight bucket, it was a 3 hole mount, not the 2 hole with the square clocking features.
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Current rides:
2016 Duke 690
2016 Duke 390
2001 DR650SE
1975 DT175B

Past rides:
2008 WR250X
2005 GS500F Scrambler
1970 CT90K2

Offline mihkels

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Re: 2005 GS500F Project
« Reply #18 on: December 06, 2015, 09:41:15 AM »
Any updates on this? I'd like to see what plans you have for the seat and the tank.
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Offline iamhiding

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Re: 2005 GS500F Project
« Reply #19 on: December 06, 2015, 05:14:41 PM »
loving the skidpad/sumpguard, thats a cool touch. end of the subframe is looking sweet as well.
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current project list:
//cbr 600 f3 fighter
//gsxr 1100 mental oldskool supersport
//gs500 daily rat tracker cafe fighter that changes every couple of month... cafe fighter?
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