2000 GS500E Adventure Bike Project

[Funderb]

this is awesome! I've been thinking of taking the gs out on the fire roads here. I look forward to its completion!

[bombsquad83]

Http://gstwins.com/gsboard/index.php?topic=58237.0

Might want to check out these chain gaurds that Adidasguy had made.  Not sure if there are any more available.  Sweet progress on this thing man.  We think alike, and I'm excited to see how this thing turns out.  Good idea to make an aluminum pan gaurd.

[Manaenrc]

Wow those chain guards are sweet. I may decide to go with a set when I have some spare cash.

Sent from my SPH-D710 using Tapatalk

[Manaenrc]

OK had some time to work on a few things this morning

Started out by working on the kick stand. With the higher suspension the stock stand length is just scary short.

Here is the stock stand, the PO decided to paint it with what looks like roofing tar 


So I was going to cut the entire stand off main mount and just weld one piece on but I decided to just splice in a piece instead. I had a piece of 1/4" Schd 40 black that was almost a perfect fit. So i cut about a 2 1/4" piece, split the stand with my sawzall and tacked in the piece.



after test fitting the tacked piece to see how the bike was going to sit I went back to the bench and welded the piece in. On stuff like this you should always use short 3/4" tacks on opposing sides to minimize any warpage.



Here you can see the welded piece. Notice I added a slight curve to the stand so it doesn't stick out from the bike so far when it's up. It is very slight but you can see it pretty well in this photo.



After test fitting the stand again I noticed that I should have split the stand below the foot tab. Now the tab is right below the rear passenger peg and will be almost impossible to put down. It was a face-palm moment LOL


So a few minutes later with the sawzall and the welder, problem solved. I also started to smooth out the welds with my flap disc sander. (btw if you've never tried one of these, stop what your doing, drive to a hardware store and purchase one. Then proceed to grind away the evil around you! They rock!)


So that brings me to the end of my little stand extension. Now my wife can't tell me that my stand isn't long enough, It's just right!

Stand up


Stand down



With that project out of the way I decided to start looking at the front fender. Within 15 min or perplexity I devised a simple plan to raise it about 3/4" this should give the new tire enough clearance and maintain the stock look.


Also here is a shot of the stock front bearings that I was talking about earlier. It seems like a design short coming to only put seals on one side and then not pack the inner hub. Well this is what you end up with, dry balls that just burn up 

[NonFiction]

[snipped for length]Fork braces maybe you could get from another forum member.   There are a couple of threads selling beefed up aluminum braces.  Maybe they could even make you one without the holes in the middle for the fender, and you could make yourself bracket for a super motard type fender higher up.

http://gstwins.com/gsboard/index.php?topic=57028.0
http://gstwins.com/gsboard/index.php?topic=59323.0

[snip again]

I know from experience that a flat fork brace won't fit with a high profile (eg rear dualsport) tire, without some sort of spacer/standoff. Trying to sort that on my own bike ATM. Following the thread, as I'm building something like this too. I say 'building' but I mostly mean, 'thinking about next steps on' my project. 

[Manaenrc]

I know from experience that a flat fork brace won't fit with a high profile (eg rear dualsport) tire, without some sort of spacer/standoff. Trying to sort that on my own bike ATM. Following the thread, as I'm building something like this too. I say 'building' but I mostly mean, 'thinking about next steps on' my project. 

What I did was notch my fender so the front brace mounts on the fork slide into the fender. Then I added longer bolts and brass shims that are about 5/8"  to 3/4" thick so this raised the whole works (including brace) that much. From my preliminary measurements it should fit just fine. If not I will just make some thicker shims to raise the whole thing up higher. 

Right now I have about 3 1/2" between the fender and the rim. I think I only need about 2 3/4" to clear the tire.

I will find out this coming week when I mount everything after I complete my inspection. I am just waiting on a rear brake rotor and then I can go get it all done. Tracking says it will be here Wednesday

[Manaenrc]

OK doing some more research and found these on ebay I think this fits the bill perfectly. I am not one for the whole carbon fiber look but they match the bikes color scheme perfectly

http://www.ebay.com/itm/UNIVERSAL-BARK-BASHERS-MOTORCYCLE-GLOSS-CARBON-BRUSH-HANDLE-BAR-HAND-GUARDS-PAIR-/260954445469?pt=Motorcycles_Parts_Accessories&hash=item3cc218d69d&vxp=mtr#ht_5697wt_1396

[Manaenrc]

OK I'm stoked, just tracked my rear brake rotor. It is out for delivery Woohoo!! that means I will be able to get the bike inspected, titled and tagged early this week. Which means that I can get the tires and seat squared away.

[Mke723]

Im sure u have looked into both motorcycle and dirt bike hand guards, have you looked into any Snowmobile handgaurds?   My sled has them and they are very very durable in cold weather, so they won't get brittle.   Ohh and they are all super inexpensive right now since the winter was not a big snow year.  Just a thought for ya.

[Manaenrc]

thanks, I will definitely check into them. I am probably about a week or more out on ordering that stuff. so I have some time to look around. 

I received my new stainless rear rotor today, 2 days ahead of schedule. I promptly ripped the rear tire off and mounted it along with the new brake pads that I got last week. Took the bike for a little spin and everything is working perfectly. No starving for fuel like it used to.

I think I may bump the needles up a little more still seems lean in the mid range. Of coarse it is also a very chilly day here so things may change a bit as the temps come up towards summer.

Never received a response from Race Tech about the front fork setup. That's not too confidence inspiring when it comes to purchasing their products.

Hopefully by Wednesday evening you will see pictures of this bike with the new tires and finished seat.

[Manaenrc]

OK so here is the instrument cluster. The PO lost the two colored lenses for the turn indicator and the high beam indicator.



I checked online and the only way to get these is to purchase the entire instrument cluster. That's not gonna happen. So I may end up building something custom. Unless I can find another panel that the instruments mount to at a reasonable price.

Unless you guys have an idea..

I check around for a panel mount lens (ones like you see on control panels) and there is really nothing that matches the size of the current design. Another option would be to take LED indicators and replace the entire socket.

Anyway  bikes ready to go for inspection on Wednesday morning and then the fun can continue.

[Funderb]

apparently adidasguy has a pile of the lenses in green, if you care what color, yours are, youll need to find another source, but really....

my HB indicator went missing, just stuck a circle of blue painters tape over the hole. permanent fix. really.

[adidasguy]

Yes, you can put in green for turn (which is what newer bikes use) and a red for high beam. I think a blue LED will shine through the green cap but not much through the red. (The caps are not a perfect filter.)

[Manaenrc]

I'm trying to get the cluster from the other parts thread. If he doesn't get back to me I will hit you up for some greens.  I currently put a blue and yellow bulb in the turn and HB indicators so the greens will probably work too. But it would be nice to have the whole part to re-finish and put on my bike.

[steezin_and_wheezin]

i have a busted bezel from my last pick. i was going to toss it, but i'll check and see what jewels i have. i'll give them to ya for next to nothing

[NonFiction]

I know from experience that a flat fork brace won't fit with a high profile (eg rear dualsport) tire, without some sort of spacer/standoff. Trying to sort that on my own bike ATM. Following the thread, as I'm building something like this too. I say 'building' but I mostly mean, 'thinking about next steps on' my project. 

What I did was notch my fender so the front brace mounts on the fork slide into the fender. Then I added longer bolts and brass shims that are about 5/8"  to 3/4" thick so this raised the whole works (including brace) that much. From my preliminary measurements it should fit just fine. If not I will just make some thicker shims to raise the whole thing up higher. 

Right now I have about 3 1/2" between the fender and the rim. I think I only need about 2 3/4" to clear the tire.

I will find out this coming week when I mount everything after I complete my inspection. I am just waiting on a rear brake rotor and then I can go get it all done. Tracking says it will be here Wednesday

Makes sense. I'd love to see a picture. Haven't done mine yet.

[bombsquad83]

I wonder if there is any way to correct the error in the speedo that will result.  Maybe you should go with an adjustable aftermarket speedo anyway?

[Manaenrc]

Makes sense. I'd love to see a picture. Haven't done mine yet.

When I take the front tire off to mount the new tire I will snap a few shots of what I did. It was very simple took 10 min with a dremel.

[Manaenrc]

Makes sense. I'd love to see a picture. Haven't done mine yet.

When I take the front tire off to mount the new tire I will snap a few shots of what I did. It was very simple took 10 min with a dremel.

since most stock motorcycle speedometers report too fast I was hoping that it would only be a little off on the slow side. But once I get the tire mounted up I will check it with a GPS. It's not the end of the world unless it would be way off which it won't be because we are only talking a difference of about 2" in Diameter.

Stock tire being 22 1/4" high
New Tire  24" high

That's only about a 7.29% difference which means that if the speed says 55 it will now say about 51.

I have a feeling the speedo is off more than that right now.

[Manaenrc]

i have a busted bezel from my last pick. i was going to toss it, but i'll check and see what jewels i have. i'll give them to ya for next to nothing

cool if you could check it out and let me know that would be awesome.