Very simple GS500 2003 project **PICTURES NOW WORKING**

[puglia-gs500]

This project started when I was given an imaculate GS500 with less than 10,000 km on the clock, thank you Edoardo

I was thinking of just using it as it was but then my Dad and Edo (with his new bike license) started talking about modifying it. Edo had endless enthusiam and kept sending pictures of "cafe racer" stlye GS500s, so I had a look online to see what I may be able to do with it and found this forum. I started with the idea that I absolutely didn't want to modify the frame so that I could just put it back to the original condition when I was done with it. That changed as soon as the new seat arrived and I got the old seat and plastics off. I knew the top of the frame would have to be sorted and then it was obvious the rear pegs had to go and then the project was really on it's way.

I thought I would post a few pictures and a bit about my bike here to give just a tiny bit back compared to all the information that I found here.


Here is a picture of the bike when I was given it



Here are a couple of pictures of work in progress with a lot of help from my Dad.





And here is a picture of it finished (but not with the second generation number plate holder)



Another picture of it finished (now with the second generation number plate holder)



There was no welding because we don't have the equipment. This was all done with simple tools, the only  tool I had to buy was a rivet gun that would let me install threaded inserts into the frame as I could not weld on tabs or brackets.

Here is a list of the parts that I bought to make it happen, with links that may work, I had never added it up before but from the list below it came to €625

• Aluminium motocross bars €20 eBay
• 7" LED Headlight €55 MOTEA
• Seat €50 MOTEA
• Indictors €30 MOTEA
• LED Flasher Relay €20 MOTEA
• Mirrors and mirror extenders €30 + €20 Amazon Amazon
• Tail light €40 MOTEA
• Exhaust €150 Delkevic
• Battery €160 Acewell
• Chain Guard €50 Stein Dinse

In addition to the pieces listed above that I bought there were a few other items needed / added

• To make the under seat electrics tray I bought a rivet gun that let me install threaded inserts into the frame €30 Amazon some sheet steel and some 2cm angle finished it off.
• I upgraded the cluster lamps and clock lamps to LED €10 + €10 Amazon Amazon
• After installed the LED lamps I had get 2 diodes and do the to get the indicators working, this post made it very clear and it took me about 2 hours in total
• I started with a numberplate holder from MOTEA but it broke really quickly so a local fabricator bent me a piece of 2mm galvanised steel.
• A plastic wedge to get angle the tail light down for better visibility, another part from the economical fabrication service supplied by my dad.

I am very happy with my new bike, it has completely resurrected my love of bikes. I would welcome any comments, criticism or recommendations from the members here.

If you have any questions on how any of the modifications we made please ask I will be happy to explain the best I can.

[Roofaloof]

Great looking bike! You did a really good job changing the look of it with the tools you had available 

How do you like the Delkevic exhaust? I'm thinking about getting one for my bike.