Gs500

[Mekanix]

I think its the exact same battery, from what I see they are both LiFePO4 .

Same technology and same cell's inside.
I can't find anything that says there is any technology inside for load balancing on either of them.

They both run the bike the same way and get charged the same way.

Only difference is that the ballistic battery has a balance charger port.

It would be easy to add one to the other pack.

I do like the ballistic pack for the nice casing and the price is almost the same for both.


Either way, That's a few paychecks down the road :P

I got a another rotor magnet today from a donor engine.
While I was there I got the two piece pushrod for the clutch, The Stator, The rotor and pickups and a few little pieces for the Frankintwin.

[droyce]

Looking good man! Its so clean like its being assembled on the factory floor.

[Mekanix]

Just Kitchen floor,

Production output: 1 unit per year

[Mekanix]

Another pic.

Did some minor painting and added the rear fender.



I tried painting my engine covers with duplicolor. That didn't work out. 3 coats of primer, then sanding. Then three coats of paint and 3 clear.

Its so weak that I can scratch it off with a fingernail.

Not sure what to do with it but I might just strip it off and try another paint or get them powdered.



I have another problem now. I have to clean the base out because of the stuff that usually falls in when you pull the cylinders off. I was thinking of using brake cleaner and spraying anything I can get to from the top. and pulling the pan off to get the fluid out.

Then when I get the engine back together I'm going to pre-oil it before rotating it by hand to set the rings.

Just below the ignitor cover there is a bolt. This is the pressure test port.

I took a spare plug and drilled through it it and taped it for a hose fitting.

[Mekanix]

noticed something.

If anyone is swapping in the two piece clutch pushrod you have to cut 8mm off the small rod for it to work with the original corkscrew mechanism.

Or use one from an 1983 and above engine.

[pete]

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...

[Mekanix]

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

Id like to polish mine but they were too pitted.

[pete]

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...

[Mekanix]

Hmm' maybe its the early/late 82 thing?

[Mekanix]

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.

[pete]

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

[Mekanix]

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.

[pete]

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.