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

[adidasguy]

Got a fork set today from Pinwall Cycles. Nice shape and good bearings.
Will still replace springs and seals. Might as well do everything before putting on a bike. Looks like one seal is a little off due seeing a little gunk on one tube. Kind of like I see on Junior's right tube.
Good straight forks are so hard to find. Now we have 2 sets - this one and a set from oregon250exc.
We'll fix up - put a set on Junior and a set on the bike build then probably sell the extras. So much easier to rebuild parts OFF of a bike in the new cave then take half an hour to put on a bike. Less down time of a bike, too.

[adidasguy]

Continuing putting new seals in forks. Started cleaning up frame and prep for painting. Continued sorting out parts.

[adidasguy]

Another frame came in today. This one is a 1993 - had been cleaned and repainted. That will save me a LOT of work.
Change of plans: Originally we were going to build one bike, put Trey's motor in it and put the 2006 motor into Trey.
Well, I decided it would be easier to put the 2006 motor into a clean frame and build up the remake of Trey that way. As the bike progresses, parts will be taken off of Trey and Trey's motor will go into Dave's bike when that frame is ready.

Here is "Phenix" (6 characters allowed for custom plates). already has a license plate for going on the road. 
Called him that because he is rising from the ashes (i.e. bike cave full of parts)


Interesting if the title is clean, Washington does not require an inspection or emissions test. You can title a bare frame for motorcycles. Imagine that! 

[knowles]

A little while ago you were taking about the 89 frame that has the factory 12volt outlet under the seat. On mine that is were the starter cilinoide is. They must have changed mid year, on bike bandit you can get both. now I see they are over on right instead of under seat.

[adidasguy]

Interesting about that. I've only seen the starter on the right.
I found a European parts catalog. Quite interesting. It even has part numbers for the 3 different types of OEM clip ons for the GS500 - the 1989's USA that we see and the 2 types from Europe (and Canada I think as that's where Junior came from and had the non-USA type).

[knowles]

Don't know about Canada, on cheap cycle parts, and bike bandit the 89 ek has both starters cilinoides for my bike, when i got it itwas located right where the 12volt put is on yours, I put a different wiring harness on mine from a 2000 and changed the wiring to match my cilinoide, but that was the only rhing that I had to change. The wiring is simpler the way they have it know vs mine but i didnt want to replace my cilinoide when it is working.

I was also looking at that front set of forks you got, because i have to replace my fork seals anyway, but you beat me to it. Have you tried the r6 shock, or any other up grade shocks for that matter with the cast iron shock mount? 

[ghostrider_23]

adidas,

I definitely envy you not only for having a bike cave but having the funds and ability to get a bike like this and put it together. You are going to gain so much knowledge of how the GS works after this projects done. I  was able to purchase a great set of current carbs that I will take apart to really understand how these little suckers work. I have had my eye out for a cheap GS or engine so I could mess around with it.

[adidasguy]

Selling lots of old collections (like Kliban Cat stuff, MAD magazine, bowling, etc.) to clear out years of collecting is providing lots of funds.

Once I get Trey running again, I will start assembling Phenix. I now have all the parts. First will come the side & center stands. Then a cleaned up 1989 knuckle & 2009 shock. 2009 forks with new springs. (I love the cast aluminum ones only used in 1989) then wheels.

I appreciate the complement - however the "ability to put it together" has yet to be seen. We'll see how it goes. If I don't know where something goes, at least I have a 1992 and a 2009 to compare to.

Photos will start being posted very soon.

[adidasguy]

Phenix officially started today - Jan 1, 2012

First: 2009 shock, cleaned up 1989 knuckle (I love the cast 1989 knuckles, all bikes will get them because they look cool). New lowering links. Set for standard height. Could set to lower if ever needed.
Then decided to put on side and center stands.
Everything gets greased. All screws & nuts get thread lock.
The frame was so expertly painted by the PO that all I had to do was wipe it down with a damp rag. I still don't know why it was parted out. Even the side stand and center stand were cleaned and painted by the PO. As bike was parted out, I bought the stands separately, not expecting them to be so nice. I did use cleaned bolts, bearings and springs.
I will drop off rims to Aurora Suzuki  for new tires.


These parts look sweet. Like a new bike!

[ben2go]

Nice looking parts.Looks like you are off to a good start.Score on pre painted items.

[adidasguy]

Found problem with one peg mount. Seems pretty bent. Took measurements in a variety of places and the frame is straight and true. Looks like an engine had been put in and a rear wheel. Not sure the story - as if someone was spending lots of money to rebuild a bike then gave up. Other than this, the frame is beautiful. Many screw holes were never used - that is they were clean with either surface rust or paint overspray. I do not think this frame was ever put back together and driven on the road. Too clean and shiny.
These peg mounts are there just because I wanted to see how bad it was. probably will put Gimbel on him.
Now what to do about this:


Straight and true. Stuck a rear wheel in just to see if everything else looked straight - and it did.

[ben2go]

I had a frame that had the peg mount bent like that.I clamped the frame to my friends steel welding table, and used a 36 inch pry bar through the peg mount, to bend it back out.The metal in that area is fairly soft and weak.

[adidasguy]

While reading replies and deciding the best options for the bent peg mount, I decided to clean some parts with a new vibrating parts cleaner. Easy: easier and less hassle than cleaning with kerosene. Put parts in, add cleaning compound, turn on, come back 10 hours later, put in polishing compound, another few hours and WOW! Like new shiny parts!
The before and after.....

[reload]

wow, let me clean the drool off my face hahaha.

tell me more about the machine you are using?

[BrianKD]

+1 What kind of cleaning machine?

[adidasguy]

Vibrating cleaner from www.Eastwood.com 
http://www.eastwood.com/18-lb-vibratory-tumbler-kit-inc-2-bowls-and-media.html
They have a small one for $99 and the large one I got for $249. The large is better due to size of bike parts --- bolts, brackets, dog bones, sprockets, etc.

Think of the time it would take to clean just that pile in the picture if you used a brush and kerosene. This thing also removes rust and paint from parts. This is one tool that is really worth the investment. You may not think $249 is worth it - until you use it.

As a suggestion: They sell a new cleaning and polishing liquid combo. Meh. I think their Metal Wash for cleaning and the crushed shells for polishing (comes with shells and green pyramids) work as well or better and are cheaper. Worth trying it. You might like them better.

Metal wash: (They have smaller sizes. Also great for hand cleaning of parts)
http://www.eastwood.com/metal-wash-28-oz.html

Cleaning and polishing liquids:
http://www.eastwood.com/eastwood-s-tumbler-additives.html

[adidasguy]

Got in a few parts today for Phenix:

Shorai battery
Shar-fins (not sure if I want black or silver - might go all black extras on the silver frame)
R&G bar ends
Smoked lenses for turn signals
Cool tail tidy for license plate and turn signals - if I decide to shorten the tail or use the Balu Racing under tail (have 2 of those, not sure why)

[Kijona]

Got in a few parts today for Phenix:

Shorai battery
Shar-fins (not sure if I want black or silver - might go all black extras on the silver frame)
R&G bar ends
Smoked lenses for turn signals
Cool tail tidy for license plate and turn signals - if I decide to shorten the tail or use the Balu Racing under tail (have 2 of those, not sure why)

I like the way that battery is packaged.

[steezin_and_wheezin]

how's the plannin coming?

[adidasguy]

Right now cleaning up the 2 1/2 bikes worth of parts I picked up and busy selling parts.... while cleaning parts and sorting what I need.
As soon as it warms up a little I'll be putting more parts on. Painted the side grab rails and got them on. I want to put new springs in the 2008 forks I got so I can put on the front triple. Wheels are at Aurora Suzuki. Front wheel bearing spacer just came in so they are finishing the wheels then I'll get the wheels on.

I like the simplicity of the old carbs. However I have about 6 sets of new carbs and wiring harnesses, so will probably go with new carbs and wiring even on the old engines.