GS500E -80 Cafe Racer Project

[bennpeter]

So now my brand new (1980 model) Suzuki GS500E has arrived. And the disassembling has started I think the process is just as important as the riding, so I started out disassembling the carbs today and sent it for ultrasonic cleaning.



The original air filter box will never get back on, after struggling like mad to get it disassembled. I just have to get the carbs cleaned and replace the O-rings at the intake. Think I could use nitrile O-rings. Should be oil-resistance and take 110 C. Then new shims, and rejet before synchronizing carbs.

I?m gonna get a 4-1 exhaust system, K&N filters, rejet carbs, new front fender, new seat with built in electrics and battery in the rear, and some mod for the instruments. Not sure if it will be clip-ons or TT handlebars. I might lower the front by 1", and then the TT handlebars would not work. This bike should be able to put on a low-carbo diet and get rid of at least 25-30 kg. Wish I put it on a scale before I started, but guess I could just read the weight of whats left off when I?m finished...

 

[Taszilo]

Hello,
I also have a GS like this with a terrible wiring. Do you have a wiring diagram for this model?

 

[brendan4]

like you i also plan on getting rid of the airbag on my gs500e but can't find specs on the jets to know what size i should reject them to to compensate for the more air flow pods will allow, any help?

 

[steve murdoch]

Brendan, do you have one of the 1980 Euro spec bikes with a four cylinder 500cc engines? We got a 550cc engine in North America.
If so, i have seen pics with both CV and VM carbs so you will have to provide some pics of your bike.