West Seattle GS500 Build from Scratch - WE DID IT! Meet PHENIX!

[adidasguy]

We're going to build a GS500 from the ground up. Frame, carbs, tank and tail came in today (from an 89). We got a free 2006 engine (needs starter and clutch push rod).


Actually, the blue will probably go on Trey (I like blue) and Trey's purple will go on the bike we build since it is for centuryghost's wife.

Bike cave is taking shape for the build. Another couple weeks and the cave will be ready to start.


Installed one of the most important pieces of equipment:


A small portion of other parts:


Full of old crap before I started cleaning it all up. Back wall was already finished.


Progress being made in cleaning up the cave and installing more wall cabinets


More photos as things progress.

[pookiebear]

awesome! I always wanted to do a "ebay" build just to do it.  Last bike in a box build I did was an xr200 dirtbike. That was fun.  Might do a xr600l next time. Keep the pics coming!

[ben2go]

Nice start.Wish I had that kind of space to build in.All I got is a car port and dirt.

I did a frame out build on my bike.Now I am ready for tear down,paint,and PC.I got one that is just a resto to running condition and a completely bare frame build.It will be a trike project for the GF.I have 4 bikes total and may be picking up a few more.

[adidasguy]

The "bike cave" is nearly ready for the project to move in and begin. Giving floor a week to really harden before "moving in". Until then, I've been acquiring a few parts I know I didn't have for the bike build.

[ben2go]

Dig the blue floor coating.Really brightens the space.

[reload]

garage looks awesome. so freaking jealous.

gluck with the build. i will be watching

[cbrfxr67]

Really ready for this.  Adidas you're great at taking pictures, so this is really going to be fantastic, seeing how you get it put together.  Not to mention, first project in the bike cave, damm I mean utopian bike garage mahal,....

[jacob_ns]

A small portion of other parts:

The OCD in me is screaming right now. I'd have all of those parts bagged, tagged and organized.

[adidasguy]

They will all get organized starting next week. Needed the bike cave first - then comes sorting out the parts - then comes selling off the extras.

[adidasguy]

Some parts were delivered by oregon250exc. They are kitty approved.
Is it ironic that before the cave is finished, before any of my bikes get to park in it, a parts frame is first to lay down on the floor?
We're getting ready to begin our build. First we strip down the frame to clean and paint it and continue to gather the necessary parts. This weekend we will start to organize the cave and who knows what we'll find in all the parts boxes.




One frame is for the build. The other will be to replace a twisted frame on one of our bikes. Forks will first be rebuilt and go on Junior, whose forks will then be rebuilt for the bike build. We really do a lot of parts cleaning and swapping. Handy to have so many of us with GS500's so we can fix & swap parts. Welcome to the world of the West Seattle GS500 Club!

[cbrfxr67]

'rrrgg arrg grrrk, yummy foot peg' sorry I couldn't help it hahah

Can't wait to see this come together!

[lucky4034]

I'm lovin that custom seat 

[adidasguy]

Got started stripping down the frame to clean and replace ichy parts (like bad steering bearings). And to our surprise, we found what appears to be a factory 12v outlet mounted to the battery box! Another odd thing was one rear turn signal had a double filament bulb and was wired that way with 3 wires except the 2nd filament wire was not connected. Seems there was a turn signal that was made and wired for running lights. Also found that a 1989 frame does not have the hole to get at the shock mount. Frame welding was a little different than later years, too. Also the 1989 frame had a cast shock mount rather then what we usually see made from bent & welded steel (you can see it right in front of the plastic parts box, behind the turn signals and rear light)

[scottychop]

Looking good man.  Wish I could have made it over.  I love tearing things apart.  12volt outlet between the legs huh?  How about a heated seat!

[adidasguy]

There's still plenty of tear down to make you happy. This is frame #2 of 2 so plenty of things to take apart 

[CarlosMendoza]

Very nice bike cave ... Very jealous. My wife would never let me build a bike in her garage. . Good luck with the build.

[jacob_ns]

I can't wait to do this to my bike this winter. Keep up the build progress!

[adidasguy]

Cleaned the cast knuckle that was on this bike. Odd - never saw that on a GS500 before. Could it be from an early production run then they changed it when they ran out of them? Anyway, it cleaned up nice and will go on Trey then Trey's will be cleaned and go on this bike. It IS an EXACTmatch for bolt size and dimensions, so we know it is not a Kat knuckle or from somewhere else unless anyone knows of a bike that had the exact same knuckle as a GS500. (PS: The parts diagrams DO show a cast knuckle for K and L models, and the steel one for M and onward. Anyone else ever have a cast knuckle? Also see the knuckle is a different part for the "F" models than the older ones  )

Not sure where the Kat shock will go since Trey will get a cleaned up stock shock and this build is for a light weight person. We clean up and recycle parts from bike to bike. That way we have very little down time on a bike. Forks will be re-springed and go to Junior. Junior's will then be cleaned and used on this build. Minimal down time on a bike. Plus it is interesting to discover differences in models from different years.

[scottychop]

Thought about grinding down the cast marks on that knuckle and then mirror polishing it up?

[ben2go]

My 89 and 90 had the cast knuckle from the factory.