April 9, 2016 at 8:10 pm #3665
My name is Cameron and i have a project GS500! It needs alot of work and attention to get her how I want it but it’s going to be a nice ride (I hope)
My plan is to put a SSSA, new subframe and USD forks on. If anyone has a guide for sticking maybe a R1 subframe or something with the “dolphin” tail look + Shock info for a VFR400 NC24 swingarm. PM me or reply in this thread
Here is my journey so far.
This is what it started life out as, A track GS500 which had been trashed and then stored for 1 year or more.
Taking a look under the “hood”
I attempt to fix the brake sticking problem the last owner told me about.
Typical to find a GS500 with rust on… Right?
I find the pistons seized and shoes are close to dust. I replaced all the pistons and got them all sorted. (No pics of the new ones yet.)
This is the broken stater solenoid, i have since replaced this and it turns out it’s not the problem, im guessing the previous owner had a remote start on the bike as theres wires for it because the ignition button does not work.
Typical GS500 problems… The head bolts have sheared and seized in. Still trying to fix this 🙁 might even buy a new engine if its cheap enough.
My new SSSA and old exhaust with the lazer can, i will be cutting down into a stubby 😛
Took me a hour trying to get the back wheel off as everything is rusted to oblivion. Penetrating and hammering until i finally prevailed!
After the back wheel was removed i started to remove the swingarm… BAD IDEA. The whole shock linkage is extremely rusted in, im either going to have to buy a new bigger ratchet, get some heat on it or saw through it. Always remember rule number 1 with a GS500, COPPER GREASE!
Finally got the shock linkage off, i cannot remove the bolt securing the dog bones but the rest came off 🙂 blowtorch ftw!
The SSSA i have is slightly too big for my frame, by roughly 2MM. so ill take it down to the fabricator when ive got some spare time and see if he can mill the sides down. I also put my refurbed brake caliper back on the front, seems the braided hoses wont reach now though :p going to have to attach the hoses first and then attach it.
Got some longer braided hoses today 🙂 buying them in red when the bikes being sprayed though 🙂
Thought i would check the air filter today, maybe clean with some compressed air i bought… Better be some powerful air to blow rust off…
Ok the SSSA is around 1 inch too big, going to have to machine that down. comparison:
Pulled back the rubber today to find the most amazing thing ever! A broken clutch lever and snapped bolt that keeps it tight, so thats a new assembly + cable i need to buy…. Well atleast you can get them in red 🙂
Wanted to check my front sprocket? there was like 3 years worth of GS500 dirt and grime inside it…. I need to invest in a jetwasher, the degreaser isn’t working! it’s almost rock solid dirt.
Thats my story so far, i will update with more pics as i get more time.April 9, 2016 at 8:22 pm #3672
Hey all just a update: Ive been working alot and looking after my heavily pregnant girlfriend so the bike is on the backburner for now. But this is what ive finally managed to do!
Ive spent 3-4 hours trying to remove my engine… No joke the bolts are seized in.
Ive started sanding down the tank, which is full of rust 🙁 but i was thinking about buying a nice new 2001+ model tank for a new seat to sit on.
I took the carbs, air filter box and wiring loom out to reach the engine.
This is the bolt that has thwarted my attempts to remove the engine… So i brought the saw out.
A nice pic of the seized rusty rear brake 🙂 good job i dont need that!
The snapped off tach cable 🙁
The front end light damage that came with the bike.
The moment ive spent 4 hours+ working towards! Im smiling really hard atm 🙂 means i can get the seized manifold bolts out and get the frame sorted for the SSSA.
In the hard process of removing the engine i snapped off a spark plug… I also broke my brake lever in the struggle! (Worth it!)
These are all pictures of how the SSA sits using the GS shock (which is too big by 110mm!)
Hope you all enjoyed this update, i sure did 🙂 now onto fitting this damn swingarm and sorting the engine out.April 9, 2016 at 8:23 pm #3673
New update, The guy who was getting my seized manifold bolts out said he would no longer do them because the whole engine had bolts seized everywhere. So i went and spent £40 on some new longer, stronger and bigger tools!
After going to work on the engine with said tools here are my results:
Valve cover off! them bolts were way too tight, obviously not to torque.
Just a picture to remind me where they were when i removed the camshafts.
After the removal of the camshafts i started to remove the shims and followers, I placed them in seperate bags detailing the letters from where they came. I also kept the chain tight so it didn’t bind or get lost in the nether of my engine.
Havent taken a picture of the header removed yet but it took a slight pry with the back of a hammer, i took care not to damage the fins on the engine. Ive bought all new o-rings for the bolts holding the header in.
Also to highjack my own thread, Does anyone know where i can buy different Engine emblems for the GS500? it’s 88mm dia.
^^^^^EXAMPLE^^^^April 9, 2016 at 8:25 pm #3674
Am i alone? Seems im talking to myself :p
Well i took all the front end off today, was the easiest thing for the whole bike!
I then removed the right side footpeg which was stuck in, Still need to drill out the screws that hold the rear brake line as the screws are rounded off 🙁
Really struggling with this swingarm though, it doesn’t fit and the linkage is backwards from the GS. If anyone has some ideas on how to get some dogbones and shock on that please tell 🙂
This is how the Swingarm sits without being in position.
Where is would sit if it was in position.
Just need a new subframe welding (need this pristine 08 tank first) Then onto powder coating, then spark erosion the bolts out of my header. and rebuild commence 🙂 Ive replaced most bolts today to not rust and seize 🙂April 9, 2016 at 8:27 pm #3675
Sorry for the silence, had 2 bikes stolen, had to buy a third, girlfriend had my baby son 🙂 , Moved out into a new house, Had to buy all new appliances (Perks of living with parents…) bought a whole new swingarm with wheel etc. Heres how the bike sits at the moment.
Pictures before cutting more of the subframe and painting.
I’m probably going to reweld the subframe then fiberglass it like a cafe racer seat without the “hump”
Need’s shock mounting point rewelding, exhaust needs re-bending to go upright.
GS seat latch on the ninja seat, getting it to fit required some grinding
Polished the exhaust too, way too much crust on it for my liking
After taking the cylinderhead to a spark eroding company, i put the engine back together but it wasn’t firing. Turns out i put the camshafts on backwards or the timing was backwards, not really sure what i did. Also had to drill out the front engine mounting bolt as it was seized.
Because of the preload adjusters i couldn’t fit my renthals so i had to swap forks but the others weren’t leaking so here goes.
This is what i was going to do before i got renthals
Here’s my attempt at fiberglass, first time even using anything like it and i think it turned out ok.
Tape and protect everything first :p
Ive got a off-set sprocket being made as the swinger is slightly off on the chain. Also same people making me a custom dash that just holds the GS speedo and the lights. Then using a PVC end cap as the surround for the speedo. Because im broke now :p
It runs also needs repainting etc.
The crappy blowing sound is because there’s no gaskets in exhaust, it’s also too loud for my phone to pickup sound wise. It would never pass it’s MOT in a million years so looking to put a baffle inside.
There is a motobatt for it but i didn’t want to flatten it so used a crappy old one for that.
I need to rewire everything as it’s all too long / doesn’t fit etc. Seen an add for motorbike electric replacements in streetfighter mag so might get a catalogue from them.
Also, the ground? that is attached to the negative terminal wire i snapped it off and it wont solder back on, how would i get it back in if solder doesn’t work?
Big update, bikes welded in, needs loom shortening and glassing. Oh and a slightly longer chain.
Diy offset sprocket, fits perfectly.
Chain lines up perfect, just the length that needs sorting.
I get 1 day off a week and no garage so if it’s not sunny I’m screwed.
Only a few jobs to go, they will have write ups on them.April 9, 2016 at 8:29 pm #3676
Ok so the swingarm is in.
I had to overcome to srpcoket issue by welding a collar onto the end of the shaft which had a circlip groove in, i also put washers on :p
Abit bodge but only thing that would work as cobalt didn’t cut through the shaft.
my mate lost his keys for his disclock so i brought my grinder and cut his monkey metal lock off so he could help me with the swingarm, thats his boot in the picture.
Front wheel on now, bodge fix for the oil resi for the shock also :p cable ties which would later snap and the resi hit my wheel scuffing my paint 🙁
stilkl need to go back to renthals on the front bars and spray my crash bars and grab handle.
Good job ive got another day off to complete this 🙂May 12, 2016 at 7:36 pm #3693LewisModerator
Looking Good !
You must be logged in to reply to this topic.