1993 re-hashed

[ShowBizWolf]

It's just a guess but the PO might have been trying to use the RTV to hold the tank trim on. That first pic seems like overkill though.

When I got my bike, it was missing the trim completely. When I bought the OEM replacement stuff, I found that it stays on without the need for any adhesives 

If you're curious, it's number 4 in the diagram here:
https://www.motosport.com/oem-parts/suzuki/1998/gs500e/fuel-tank%28model-w~x%29

[Sporty]

It's just a guess but the PO might have been trying to use the RTV to hold the tank trim on. That first pic seems like overkill though.

When I got my bike, it was missing the trim completely. When I bought the OEM replacement stuff, I found that it stays on without the need for any adhesives 

If you're curious, it's number 4 in the diagram here:
https://www.motosport.com/oem-parts/suzuki/1998/gs500e/fuel-tank%28model-w~x%29

Thanks ShowBiz

So I see that numbers 6, 9, 10 are missing. I'm regretting not looking into this and ordering the #9  front cushion. 

Does anyone have a real photo of that (edit, it's #9) front cushion   It's not the cost, but the wait at this point.







Do you think that this universal edging (automotive style) could be used for the trim?

[cbrfxr67]

Great work! Goo gone is goo-d stuff!

[Sporty]

Man, this thing is wearing me out.  I now realize it's missing ALL the tank mounts and hardware. I just thought the bolts were out.  This is what happens when you buy a bike you know nothing about.
So now I order more stuff... or make it. 

I tried some of trim on and it seems Ok.
I can't really mock up the tank without mounts. Thoughts anyone?






I pulled the tappet shims to see the sizes. I had trouble with the motion pro tool slipping off the bucket edge.  It's hard to see, but the part of the tool the pushes the bucket had a casting or forging line and was rounded.  I filed it to be flatter and have a sharper , squared edge. It worked a bit better but still a PITA IMHO.





I ordered just two shims from Z1 (Dime City). This should put the intakes at about the larger end of spec.

The exhaust are just a little over spec, I didn't want to tighten them up to near minimum with a shim change.

It would have been nice if I could have swapped intake for exhaust (2.60. & 2.65) but that was going the wrong direction (worse, not better)

[ShowBizWolf]

That trim looks like it fits pretty good 

Gosh I can relate. There were so many little things about my bike when I bought it that I had to fix and/or replace... wow was I ever thankful (and still am) for parts diagrams!

One sentence was kinda confusing, not sure if you meant a pic of #6 (the tank trim) or the front cushion (#9)... but I went through my pictures and found this one of the front tank cushion:


I did improvise for a few years, before I ordered the OEM one. I remember I had an old rubber floor mat that I cut and layered up... then used silicone to keep it in place on the frame. I also had to put some on the tank bracket, because the OEM cushion goes on top of the frame as well as under it. From my experience, I'd order the OEM one.

I coulda sworn I had an up-close picture of the tank trim but I'm not finding it now 

[Sporty]

That trim looks like it fits pretty good 

Gosh I can relate. There were so many little things about my bike when I bought it that I had to fix and/or replace... wow was I ever thankful (and still am) for parts diagrams!

One sentence was kinda confusing, not sure if you meant a pic of #6 (the tank trim) or the front cushion (#9)... but I went through my pictures and found this one of the front tank cushion:


I did improvise for a few years, before I ordered the OEM one. I remember I had an old rubber floor mat that I cut and layered up... then used silicone to keep it in place on the frame. I also had to put some on the tank bracket, because the OEM cushion goes on top of the frame as well as under it. From my experience, I'd order the OEM one.

I coulda sworn I had an up-close picture of the tank trim but I'm not finding it now 

It was the #9 front (I Edited the typo) Your photo is what I was looking for, thanks!
I see that it's kind of fancy!

Are the #10 side cushions just little square blocks of rubber /foam rubber?
I'm ordering today at least the front #9 and the rear upper and lower #13&14

[Bluesmudge]

It took me 2 or 3 valve adjustments to figure out how that motion pro valve shim tool is supposed to work. Its a tricky thing, but once you get the muscle memory for it, it works really well.

[ShowBizWolf]

I'm glad I can help! From what I remember, those #10's are indeed just little (dense) foam cubes. When I look at the side of my bike, I can see them... so I measured one and they are 3/4" tall. They sit right on the frame.

[SK Racing]

Funny thing is the F-series with the new shape tank doesn't have the little square foam cubes (that I'm aware of), although the rest of the tank mountings are virtually the same. So what is the purpose of the foam cubes?

[Sporty]

Funny thing is the F-series with the new shape tank doesn't have the little square foam cubes (that I'm aware of), although the rest of the tank mountings are virtually the same. So what is the purpose of the foam cubes?

IDK, but did not order them at $5 ea.  I'll substitute for that (it's just foam rubber)

I thought about making substitution for all the mounts. A piece of sliced (Lengthwise) hose for the front. Rubber grommets or washers for the rear.  However, a loose and/or vibrating, rattling  tank sucks. ShowBiz's comments reinforced that memory.

[SK Racing]

This is what the mounting rubbers look like for the rear of the tank.

The steel spacer is 18mm long, 6.5mm ID, 9mm OD. There is an H-shaped rubber ring, about 14mm ID, 25mm OD x 8mm high. The second rubber has a stepped shape, 9mm ID, 25mm OD and 8mm high with the stepped part raising up 10mm, 14mm OD.

[Sporty]

This is what the mounting rubbers look like for the rear of the tank.

The steel spacer is 18mm long, 6.5mm ID, 9mm OD. There is an H-shaped rubber ring, about 14mm ID, 25mm OD x 8mm high. The second rubber has a stepped shape, 9mm ID, 25mm OD and 8mm high with the stepped part raising up 10mm, 14mm OD.

Thanks, that's way better than the parts diagram.

I know that as an isolation mount and it's hard to substitute. A lot of machinery, industrial engines and generators use those, but larger.

I put the order in for the front mount cushion, the rear mount cushions (rubbers) and spacers.

[Sporty]

A light day on the GS

The gas tank mounts are ordered.

Made a tasty Italian style pasta topping with fresh tomatoes, basil and peppers from the garden.

Then it back to the gauges and dash. The gauge cushions (Suzuki seems to call a lot of things cushions) arrived yesterday. I mocked up and thought it needed a little more clearance at the reset knob.
Since it needed tough up anyway after gringing, I decided to fix the paint on it. (It had wrinkled because I sprayed clear at the wrong time) so, it was wet sanded and received another two coats of clear.







It was dry enough to mock-up the gauges in after a couple of hours.


This front wheel hub cover came in too.  It was a match for the dark wheel, so it had to be painted silver and clear.

[ShowBizWolf]

Oh my... bike stuff AND foodies! That really looks good :nom nom:

[cbrfxr67]

ooohhhh pastaaaa

[Sporty]

This is what the mounting rubbers look like for the rear of the tank.

The steel spacer is 18mm long, 6.5mm ID, 9mm OD. There is an H-shaped rubber ring, about 14mm ID, 25mm OD x 8mm high. The second rubber has a stepped shape, 9mm ID, 25mm OD and 8mm high with the stepped part raising up 10mm, 14mm OD.

This has become extra good and needed info because the spacers are on back order. I just ordered them for convenience (and that they have to be the correct length to preload the rubber properly).

With your measurements I'll be able to move forward! 

[SK Racing]

Happy to be of assistance. 

Btw, I bought those SS bolts and washers for my current project. The original ones were steel.

Btw2, my measurements of the steel spacers are accurate to 0.1mm. I've used a vernier caliper to measure. So far I've had zero luck in finding spacers locally. So, I hope you have better luck, or maybe you can machine it yourself since you seem to have all sorts of drool-worthy shop equipment.

[Sporty]

It was the night to finish up the instrument cluster..(or whatever it's called)

I installed six of the very common 194 bulbs. They are brighter and much longer life than the 158 bulbs that were in there..  Tested them out before assembling.




Then I remember that it's missing ... yep another "cushion", that I forgot to order. I ended up making a crude substitute from a scrap of neoprene rubber sheet.




It's a bit fumblely putting all together






On the bike.





Overall, I think it's a mediocre result for a lot of work. It cost very little  tho,  $3. in bulbs, $12 for "cushions" and the rest was  welding, straightening, epoxy, sanding, painting, making labels,... all stuff I had. It looks a heck of a lot better than it did. A decent used set is $150-200. New parts for the plastic bucket and metal frame is over $200.

All in all, I'm happy to have one more item done and to be moving onto the next...

[cbrfxr67]

'at looks rocking!

[SK Racing]

I'd put some black heatshrink in the center section of the handlebar to hide the knurling.