First build, GS500 commuter streetfighter

[oldpara]

This project was initiated by my need for more hands on experience wrenching, and a friend and fellow forum member HJFisk who happened to have two old junker GS500's he was willing to trade for one old junker car.
Let me introduce the bikes, first we have an 89 500 with 1200 mi on the engine. In 1990 it met a black bear on the way home and sat around since then. The front end on the 89 doesn't belong to the bike, it is there just for mobility purposes.

Then we have a 2004 with 18k, the kid bought it new but never checked the oil, one day on the highway the bike said enough and down he went.

In the process of stripping them down.

After stripping them both down we decided to use the 89 frame as the 04 had no title.
Before and after stripping and priming.

I have more images of the continuing build but I'm being told I can only use 12 images per thread sooo, I'll continue this in another thread.
Any way, it's coming along well, thanks to HJfisk continued help, and instruction.

 

[cowboyup3371]

Those are some nice pictures. Hope to see more.

You realize it's per post not per thread, right?

 

[Steve]

You realize it's per post not per thread, right?

Yep, just reply to your own post with your next one. Keep it all in one thread.

.

 

[Guest]

I think I'll be tuning into this one

Very keen to see how you go... I'm sure you're aware I have a thing for the twins so definitely want to follow this one through

 

[Guest]

This has been a fun project to work on with Dana, he's been fun to work with and help on this project.

 

[oldpara]

Once we got the frame primed it was time to do a little mocking and make sure things would fit from the 2004 to the 89 frame, also to find what we modify on the frame for the tail, exhaust, seat, etc.

Looks like the undertail is going to be OK

Tank looked good

more of the undertail exhaust

Hey HJ, that was a Gixr shock we put in there wasn't it ?

Then there was stripping and working on the dented tank

And to continue again

 

[oldpara]

Guess I need to show you some of the goodies we're putting on.

The Battery

The new Reg/Rect

New can, tail, cam cover

Headlights

A little lunchbox air filter

 

[Guest]

Now I know why you were so insistent on the Shorai battery it was the girls in the ad.

 

[Guest]

Dang that is one ambitious project. Gonna be a sweet one though.

Interesting that it only uses a twin carb setup.

 

[DrunkenChekhov]

Dang that is one ambitious project. Gonna be a sweet one though.

Interesting that it only uses a twin carb setup.

There's only two cylinders?


Looks like its gonna be sweet!

 

[Guest]

Guys this is looking awesome... do they personally deliver the Shorai battery?

Are you planning on bringing the pipe in closer to the rear of the frame? It seems to poke out behind the rear tyre an awful lot in that photo... but it is definitely a very cool pipe

 

[Guest]

The pipe is all mocked up now , and only sticks out about 1-1 1/2 beyond the race tech tail section, just enough to hopefully prevent it getting to hot and melting the tail section.

 

[oldpara]

Yea, the pipe looks good with the R-1 tail on the bike, we're going to cut about an inch off the pipe where it goes into the can so it will be even shorter. Just don't want to start melting lights etc.

I am a little dissapointed in one thing though, I thought we'd be able to chose one of the girls depending on the size of the battery, all we got was a "cardboard" box......

Anyway, heres some more of where we are in the mocking up and bolting down stage.

Heres the raw pipe

Trying to get the battery box situated, the wood block is the actual size of the battery.

 

[Guest]

Good stuff guys, hard to tell with a pipe until the body work etc. is on but sounds like you've got it all covered off

 

[DrunkenChekhov]

Any progress on this sucker?

 

[Guest]

Yes ,Dana has gotten most of the small parts painted and we just started the reassemly this last weekend, I'll get after him to post up some progress, pics. The bike has been dis assembled for paint for the last 3 weeks, we still have to do some work on the tail section , and Tank paint.

 

[Guest]

Yes ,Dana has gotten most of the small parts painted and we just started the reassemly this last weekend, I'll get after him to post up some progress, pics. The bike has been dis assembled for paint for the last 3 weeks, we still have to do some work on the tail section , and Tank paint.

Cool, definitely keen to see the progress pic's!

You guys should know to drip feed us our addiction right?

 

[oldpara]

Hey, everyone.
Sorry about the delay but this stuff takes alot of time, more than I thought !
painting is pretty much complete, although small things turn up or something gets marred and has to touched up.

engine primed

engine painted

parts

And all the parts and pieces

More coming

 

[oldpara]

Now the assembly pics so far.

Frame on the bench

Shock in

New seals and fork oil with a delrin space for the spring

front end in

some headlights

new stainless brake line

and a few more on the way

 

[oldpara]

Nice new BT090 on the back

And that's where we are for the time being, waiting for some rear wheel bearings at the moment.
This has been a fun/learning project and it ain't over yet !