Gs500

[Guest]

Mate she's coming together nicely now!

Not sure what to recommend on the covers... I just polish mine...

The two piece clutch pushrod, is that the same as the 80 - 82 450's? If so, good to know...

 

[Guest]

80-82 have the one piece. 83 on have the 2 piece.

Id like to polish mine but they were too pitted.

 

[Guest]

Hmmmm I have the 2 piece in mine and the parts fiche shows the 2 piece as well. I shouldn't have said 80 - 82 because like the extra bolt on the valve cover and the non-flange clutch pushrod seal with the metal retainer they all appeared to be revisions for the '82 model year...

 

[Guest]

Hmm' maybe its the early/late 82 thing?

 

[Guest]

I need an idea for colors for the plastics and tank.


I was actually thinking of going all white

the lower faring is white after I sanded it and it looks good.

The rear grab bar is powder coated white.

I could get the tank powdered white and all that would be left is the faring and the sides to spray white. Although I just can't picture it yet and it might just be a terrible idea.

I also really liked the original color

The other option is painting it.

And something else I'm considering is to Wrap the parts and then clear on top of that.

I like the carbon fiber look but it would be excessive on this thing. Maybe just a few accent pieces


I'm open to ideas.

Right now the colors on the bike are:
Silver
White
Black


Also, Should I keep the windjammer or toss it? I have to make custom brackets for it to fit right anyways.

 

[Guest]

Hmm' maybe its the early/late 82 thing?

Yeah definitely... they changed a few things for the '82 year that's for sure.

As for colour, you need to get Tim Tom helping you photoshop, but I think an inverse of what it is now. White with blue lettering and details.

To break the white wheels up with all that white on the bodywork, maybe some blue rim tape.

And lose the windjammer, that things horrendous on the little 500! Go for a neat little fly screen if you want something there...

Just my opinion of course

 

[droyce]

I need an idea for colors for the plastics and tank.


I was actually thinking of going all white

the lower faring is white after I sanded it and it looks good.

The rear grab bar is powder coated white.

I could get the tank powdered white and all that would be left is the faring and the sides to spray white. Although I just can't picture it yet and it might just be a terrible idea.

I also really liked the original color


The other option is painting it.

And something else I'm considering is to Wrap the parts and then clear on top of that.

I like the carbon fiber look but it would be excessive on this thing. Maybe just a few accent pieces


I'm open to ideas.

Right now the colors on the bike are:
Silver
White
Black


Also, Should I keep the windjammer or toss it? I have to make custom brackets for it to fit right anyways.

It's going to be difficult to pick something that goes well with the white wheels. I've always liked white on bikes but with the wheels I don't know how it will look. I prefer bright colors for safety (orange?), but that blue is really nice. And yes, ditch the windjammer. I'm probably no help

 

[Guest]

Got some parts today.
handlebars from china, They were really light, I didn't know they would be aluminum! Also got some grips, bar ends, and full set of gaskets and seals.

I'm working on the engine for now. I had to tare the bottom end apart.

Everything seemed alright but it had to come apart to get the grit out that falls in when you pull the cylinders off

So far I haven't done too much with it. Washed the cases and a few parts. Taped the threads to clean them up. I'm thinking about painting them.

The oil pump was scored pretty bad so I swaped it out for a spare one.
I noticed that the oil pump gear is smaller on the 500's compared to the 400.
I think a set of gears from the 500 would be a good upgrade for any 400 or 450.

I have to change the output shaft bearing because there is quite a bit of play in it and unfortunately its seized in place.

Here's some pics.

 

[Guest]

Good stuff mate, so the mounting bolts for the oil pump are in the same location and the inlet/outlet holes are the same? Another very useful piece of information... We're going to have to compile a list and get it posted on BassCliff's site and the GS Twins Wiki.

 

[JEEPRUSTY]

yup it is.

I also scored a GS500 ignition for it.
ignitor, pickup and rotor.

I am fairly certain that the igntion pickup coils are the same as on the 83-86 I4 engines
Not sure if that helps but it may for future reference if one of the coils goes bad.

Extremely talented restoration btw.
I love the kitchen pictures they are so hard core.

 

[Guest]

Good stuff mate, so the mounting bolts for the oil pump are in the same location and the inlet/outlet holes are the same? Another very useful piece of information... We're going to have to compile a list and get it posted on BassCliff's site and the GS Twins Wiki.

I'll start an excel sheet for the wiki.

The pump is exactly the same from 80 to 89 for certain.

I actually disassembled both pumps and used the best of both. Cover from one, rotor from the other, shaft from the other and so on to make the best out of all of them.

Only difference is that the 500 has a brand name on it and looks like the holes are CNC'd where as the 81 I used looks like it was drilled by hand

So i'd say any newer parts are better than NOS.

Also the gears on the 500 give more flow.

The clutch on the 400-450 and 500's are different slightly. But both bolt on and you can install which ever gears you want to from both generations.
I'd go with the 500.

I'm actually getting another bottom end with a good drive train so i don't have to change the bearing on the output shaft.
And I'm going to steal the clutch and oil pump gears off of that one for the Frank
That block has a bad crank but everything else is good and I've already robbed lots of parts from it

 

[Guest]

I am fairly certain that the ignition pickup coils are the same as on the 83-86 I4 engines
Not sure if that helps but it may for future reference if one of the coils goes bad.

Extremely talented restoration btw.
I love the kitchen pictures they are so hard core.

Thanks.

Seems like Suzuki liked to reuse alot of the same parts.
I normally use this site to cross reference part numbers. They have the superseded part numbers and OEM from back in the day.

 

[Guest]

Excellent... now I know what upgrades to look for if anything ever breaks on the 450

Let's hope I don't need to though!!!

 

[Guest]

Pipes done in satin ceramic and new grab bar.

Going to get these stripped and repaint them properly. This one also has, Red, black, silver, blue, black paint on it like the rest of the bike did



Did some plastic welding tonight and finished off alright but I have to say its an art form !

 

[Guest]

Good stuff mate, love the pipes!

 

[Guest]

Not much new.

Got some SS brake lines from front and back and put them on. Bit of a difference in size !
The lines are half the diameter of the original and I went with a few extra inches for the hell of it.

I got blue, thinking back now I think silver would have been the safe bet but I'd say it should look good with the plastics blue.


Got the other block yesterday and just tore it apart.

Lets see,,, scrap scrap scrap. Might use that, nah garbage, Next, next next, What a mess

There was so much shavings that it made it through the filter and then through everything including the transmission.
The jets for the tranny are pretty small. I'm amazed how much must have made it through to have that kind of effect.

Turns out I could use it to fix mine. I needed the driven gear shaft because my main bearing was sloppy.

Then again so was this one.


I got a complete set of cases out of it though and a bunch of small parts which are always useful, eventually that is

Thinking of cleaning that block up and using it instead of mine.
Haven't gotten mine back from the strippers yet, I'm thinking of powder coating it but I don't know.

That means I have to make panels to protect everything. The Grit gets everywhere and the gasket surfaces usually get scuffed up so i'm trying to avoid that.

I could high heat enamel it and be happy with that too. I mean I have two cases and covers to play with now.


I was playing around with my old frayed throttle cable. Must have been bored or something.

I held one end on a battery and scratched the loose frays along the other post until the cable was smooth and all the frays that were sticking out were burnt off.

Then I hit that small section with some solder.

It actually fixed it up nicely. Wouldn't be good for any bends but I'd use it for straight sections in a bind. New one is installed now but I'm sure this one will come in handy some day.



Anyways,

 

[Guest]

Painted the block. Might bake it now or just let the engine do that when it fires up on its own.

Installed the volt meter and gear position in the gage bezel but I don't like it.
It only goes up to 5 and there's no way to get a 6 because of the internal design. I also repainted it black to blend it better. Actually its because I messed up while drilling the holes for the voltmeter.


Looks like I'm back to the seven segment display and lots of diodes...

But here's what it will look like.

 

[Guest]

Bugger on the gear indicator! I reckon that German guy's one is the way to go. It'd be easy enough to have the diode setup remote to the display with a short bit of ribbon cable too.

The block looks nice...

 

[Guest]

I'll use this for now to play with but I've got the diode network in the works.
I'm sure there is a chip that does it all though.


I made some progress tonight.

Reassembled the engine and mounted it in the frame.

Its starting to look like a bike again.

Started assembling the top end and then realized I couldn't do it with the engine base in the frame

I managed to get the engine dropped down enough to make it all fit.
Then I took it back off.

I was speaking to Rich (wera90ex) and he has some pistons and GR cam's that I'd like to use.
My cylinders do show slight signs of scratching so it would be for the best to bore it. And the GR cam's is just more things to have fun with.

So the top end will stay off until I get that stuff done.

 

[Guest]

Nice! And the GR cams are just a slot in replacement? What's the big difference there? More lift or something?

That stuff goes over my head but I'm still interested in seeing what difference it makes.

If my 450 ever gets tired and I have another bike to commute on, I'd be seriously tempted to spice it up a little more in the power department... I have the pipe and intake to cope with it and am now confident enough with my carbs that I could make it work...

I'd probably go solo seat, rear sets, and maybe even clip ons or clubmans if I do that too, but this is all pipe dream stuff at present...