Author Topic: '08 GS500 Scrambler Build in LA  (Read 393 times)

Offline Carltheproducer

  • Trade Count: (0)
  • Local Club Racer
  • *
  • Posts: 45
  • Karma: +1/-0
'08 GS500 Scrambler Build in LA
« on: June 26, 2018, 01:06:31 AM »
Finally starting my 2008 Suzuki GS500 Scrambler build in Los Angeles. First day (8 hour day), we took off the back of the motorcycle to measure for seat and how we're going to cut bike. And we took out the engine because it was smoking from the front engine under headlight; oil dripping out of top port and it was making an awful clicking noise when you started it up; looks like I didn't have enough oil at the time of incident. Here's what I've bought so far and what I need to buy. I would love some thoughts, concerns or helpful suggestions.

BOUGHT ALREADY
1.) Continental TKC80 Twinduro tires. One size bigger than stock. I did not get to ride with the new tires before engine problems but my friend said it was a bit bumpy. I didn't have to do anything to motorcycle to accommodate these tires on. A guy in the SFV charged me $425 for tires, install.
2.) Renthal Road Bars - Standard 7/8 (BLACK). I thought these looked cool but functionality wise, a bit uncomfortable and you can feel the wobbles for sure on the highway. I am on the hunt for something better though, any suggestions?
3.) Brown Cafe Racer Flat Vintage Saddle Tracker Seat for Kawasaki, Suzuki. I bought this on ebay[/url]https://www.ebay.com/itm/263566173178[/url] for $29.50. I get it on Friday. My buddy is a teamster mechanic and very talented welding and fabricating. He worked on a couple of the fast and furious movies. I feel confident, he can make it fit on frame. I found this LA vendor on Craiglist, great looking seats but pricey. https://wilderfactory.com/t/seats/parts

WHAT I NEED TO BUY
1.) An engine, I already knew 2 known issues with this '96 engine (the bike's 2nd motor) and this 2nd motor lasted me at least 4 years and like 15k miles I'd guess. Unfortunately, when we were taking out engine yesterday, we dropped it (we were a bit drunk at this point) and i broke off some of the fins on the engine cylinder. I am being told its fine as long as I didnt crack the casing and I can live with aesthetic damage...i dont know if my heart can bear that so I am looking for a great used motor in SoCal. I found this on FB marketplace https://www.facebook.com/marketplace/item/483014315465692/, 2007 engine with less than 10k but a compression test hasn't been done yet. $300. More info to come on this lead. I found another motor here, https://losangeles.craigslist.org/wst/mpo/d/suzuki-gs500f-gs500-parting/6621158761.html but fellas wants $1k for this complete engine, transmission, starter.
2.) An exhaust, i love the exhaust wrap look. I dont want anything too loud but not too quiet.
3.) Front headlight assembly and tail light assembly. I am just looking for a bold, scrambler look front and back but there's so many options. My top 3 headlight fav's right now. https://newbonneville.com/shop/denali-dual-dr1-headlight-conversion-kit-for-triumph-bonneville-thruxton-scrambler/, https://www.instagram.com/p/BkdzWE8hMMP/?hl=en&tagged=scrambler and http://inspiracionmetalica.com/suzuki-gs500-walking-dead/. I like what this Pasadena vendor is doing for tail light assemblies, http://maundspeed.blogspot.com
4.) Forks. Either new forks completely or awesome fork boots.

What other rookie questions, should I be asking to make this as fast, cheap and good as possible? Thanks!


« Last Edit: June 28, 2018, 08:07:31 AM by Carltheproducer »

Offline cbrfxr67

  • Some day I'll finish my projects
  • Trade Count: (+3)
  • MotoGP Racer
  • ******
  • Posts: 2257
  • Karma: +24/-0
Re: '08 GS500 Scrambler Build in LA
« Reply #1 on: June 26, 2018, 02:06:33 PM »
Youve got some great ideas going on and obviously a talented helping hand for fabbing.  I feel like you're going to make something amazing.  Cool that you're on a fast track too!  Can't wait to see more,... :woohoo:
« Last Edit: June 28, 2018, 01:51:50 PM by cbrfxr67 »
"Its something you take apart in 2-3 days and takes 10 years to go back together."
-buddha

Offline Carltheproducer

  • Trade Count: (0)
  • Local Club Racer
  • *
  • Posts: 45
  • Karma: +1/-0
Re: '08 GS500 Scrambler Build in LA
« Reply #2 on: June 28, 2018, 08:13:52 AM »
Day 2. I started to take apart the engine cylinder with the aid of this Youtube series, https://www.youtube.com/watch?v=6X0VwcdZq7M. This took about 2 hours to remove both cool fins sections of the top engine cylinder by myself with YouTube. This my friend quickly realized towards the end part of taking off the last cool fins section. A bolt was missing in this piston and the bottom half of the piston was chipped. This is not normal, right? How much work is this going to be to rebuild? Am I better off rolling the dice on a $300 used motorcycle? I would love any much insight on engine rebuild kits, piston rod replacement, etc based on these photos.




Offline mr72

  • Trade Count: (0)
  • World Superbike Racer
  • *****
  • Posts: 1732
  • Karma: +25/-0
  • Musician, Engineer, Sci-Fi Author
    • Josh's Books
Re: '08 GS500 Scrambler Build in LA
« Reply #3 on: June 28, 2018, 02:18:47 PM »
I think I'd be looking for another motor, otherwise a complete overhaul of this one is in order. The bolt that's missing from the rod end is somewhere in the crankcase, along with the hunk of missing piston. The damage those parts have done floating around is probably not small.

The other thing is to consider what it took for this damage to occur. My guess is the rod cap bolt came out and hit the piston skirt and chipped it. But how did that bolt come out? Did the bolt head shear because of stress? was it torqued wrong from the factory? Was it some kind of abuse? Who knows.

If it were me, I'd find another engine. Cheaper than rebuilding and probably less risk.


Offline Carltheproducer

  • Trade Count: (0)
  • Local Club Racer
  • *
  • Posts: 45
  • Karma: +1/-0
Re: '08 GS500 Scrambler Build in LA
« Reply #4 on: July 06, 2018, 04:49:24 AM »
I picked up a '07 GS500 motor down in San Diego with allegedly less than 10k, I negotiated this SD down to $200. My friend thinks we need to replace shift rod seal/bearing. What other things should we be testing, taking apart before we labor putting this back on the frame? It is ironic that I am going from a '96 GS motor back to a '07 GS500 as everything about this bike is '07 GS500 [3rd motor now].






Here is the seat I got in the mail, https://www.ebay.com/itm/263566173178, $29.50 all in. I like the color but it does seem a bit small for 2 people, no?



I found a LA based vendor named Unique Cycles - West Coast who makes these cafe racer bobber streetfighter hoop loop seat tail section tail light for $159, https://losangeles.craigslist.org/sgv/mpo/d/cafe-racer-bobber/6626862053.html who will patch a small decent, scratches and paint for $350 and the rims powder coated for $260. Is that a good rate? Its going to take a couple of weeks for them to do though. Here are my tentative ideas right now. What you think? I am having issues finding appropriate looking fenders, headlight assembly and tail lights. Any awesome leads?

I want to have a decal that says, BOSTON or PATRIOT.


Maybe a distressed American Flag instead of the bull's eye.
« Last Edit: July 06, 2018, 05:47:27 AM by Carltheproducer »

Offline mr72

  • Trade Count: (0)
  • World Superbike Racer
  • *****
  • Posts: 1732
  • Karma: +25/-0
  • Musician, Engineer, Sci-Fi Author
    • Josh's Books
Re: '08 GS500 Scrambler Build in LA
« Reply #5 on: July 06, 2018, 12:40:30 PM »
Yes I think that's very small for two people. After riding my GS a bit recently 2 up I am even more convinced that keeping the stock seat is the way to go. Unless you and your pillion are both under 120 lb and 6% body fat then that brown seat will be very cramped.

Offline gregjet

  • Trade Count: (0)
  • AMA Superbike Racer
  • ****
  • Posts: 503
  • Karma: +3/-0
Re: '08 GS500 Scrambler Build in LA
« Reply #6 on: July 07, 2018, 08:24:19 PM »
I agree about the length of the seat being short for two people for more than a pop down to the cafe.
The passanger footpeg position will be too far back in that seating spot as well and with a lower seat height will be very cramped. Fixable though as the peg brackets are reasonably strong .

Offline The Buddha

  • The guru Ba-moo-derator
  • Administrator
  • Trade Count: (+52)
  • Motorcycle God!
  • *****
  • Posts: 25929
  • Karma: +104/-0
Re: '08 GS500 Scrambler Build in LA
« Reply #7 on: July 11, 2018, 01:18:05 AM »
I picked up a '07 GS500 motor down in San Diego with allegedly less than 10k, I negotiated this SD down to $200. My friend thinks we need to replace shift rod seal/bearing. What other things should we be testing, taking apart before we labor putting this back on the frame? It is ironic that I am going from a '96 GS motor back to a '07 GS500 as everything about this bike is '07 GS500 [3rd motor now].


I don't think your shift rod seal was leaking, cos those are very very rare on this bike to leak. Likely it was some cheap a$$ chain lube or more likely that push rod seal was leaking, and that is an external seal, not internal, and that is a Total POS design on Suzuki's part.

Cool.

Buddha.
-----------------------------------------------------------------
I run a business based on other people's junk.
-----------------------------------------------------------------

Offline crackin

  • Trade Count: (0)
  • Formula Extreme Racer
  • ***
  • Posts: 240
  • Karma: +3/-0
Re: '08 GS500 Scrambler Build in LA
« Reply #8 on: July 12, 2018, 10:33:13 AM »
In the pic you posted of the new motor there is two bolts missing at the rear of the head, in between the carby boots. I'm pretty sure those missing bolts hold the cam chain guide. You need to pull the valve cover and see whats going on in there, that guide has probably fallen into the sump but hopefully not. Also check valve clearance while you have the valve cover off.
 
« Last Edit: July 12, 2018, 10:47:47 AM by crackin »
No matter what i do to it, it's still a GS
 It's not how fast your bike is, it's how long you are prepared to hold the throttle on.

Offline Carltheproducer

  • Trade Count: (0)
  • Local Club Racer
  • *
  • Posts: 45
  • Karma: +1/-0
Re: '08 GS500 Scrambler Build in LA
« Reply #9 on: July 22, 2018, 05:43:32 AM »
@crackin, good catch on the cam chain guide. It totally sunk down, see below. Thanks for that, seriously, thank you.



I dont know why the previous GS motor owner based in San Diego Sean M K, took off those two bolts so my buddy and I double checked the rest of engine before putting back..in...again. We found that Sean took out the pulse generator too. Here's how we discovered it once we started taken apart the motor, below.



We pulled off the pulse generator pieces on mine and put it on Sean's to the best of our ability, see below.



Then we had to pull of this screw and a little coil of my old motor and put on Sean's motor. What's this screw called and its purpose?



We put in Sean's motor faster than the 1st time, maybe 30% faster. Using the Haynes' manual, to put back the fuel tank, we could not determine why there's was 4 nipples under my '08 tank but we only had 3 hoses? In Haynes' manual, it states "the fuel hoses (A) and the water drain hose (B)" but it does not say how the 2 (A) fuel hoses go directly into the Remote fuel tap? Unfortunately, my friend and I didn't take good notes/photos of when we took off the gas tank the 1st time so did we lose a hose? Where does the other end of the water drain hose go? Is the water drain nipple closest to the fuel nipples or the one on the other side of the tank? We settled to mickey mouse the tank to finally start it up, see video.


....Why the hell did this happen?!?! Where do you think it's coming from? We could not figure it out. The red liquid is Motul 4T 7100 10W40 [MA2] 100% Synthetic oil, FYI. Any feedback, advice would be greatly appreciated! If you live in the SFV (San Fernando Valley) and want to come over and wrench with us, I will gladly reward you with gas money, beer, lunch and a great time!


Offline ShowBizWolf

  • Ninja turtle...in a van
  • Trade Count: (+6)
  • MotoGP Racer
  • ******
  • Posts: 2489
  • Karma: +61/-0
  • Support Shelly's rescue at tinykittens.com
Re: '08 GS500 Scrambler Build in LA
« Reply #10 on: July 22, 2018, 06:46:43 AM »
I saw your post in the FB group so this link should work. Check out the fuel hose routing diagrams in the "Files" section of the group: https://www.facebook.com/groups/2204918767/files/

I would post them here directly but I'm at work and imgur (where I have the images) won't work on these computers... so I can't get the link to embed them here :technical:

EDIT: I should add that the diagrams in the link are corrected diagrams. The diagrams in the manuals and on parts sites are wrong, believe it or not :cookoo:
There are also some in the wiki: http://wiki.gstwins.com/index.php?n=Main.HoseRouting
« Last Edit: July 22, 2018, 07:05:20 AM by ShowBizWolf »
Superbike bars, '04 GSXR750 headlight & cowl, GSXR1000 signals, Chuck81 fork brace, '05 Busa fender, stainless exhaust & brake lines, belly pan, LED dash & brake bulbs, 140/80 rear hoop, F tail lens, SV650 shock, Bandit400 hugger, aluminum heel guards & pegs, fork preload adjusters, .75 SonicSprings