my SUZUKI GS500E new life

Hey, all , first I would like to say that this Journal is awesome! Really whenever I have time I’m going through threads, to get some inspiration. All of this give me a reason to share something from me. The plan was a little bit different, to share the garage build as currently I do not have one ☹, but instead I have start working I would say on my first project! As it is named in the thread title my SUZUKI GS500E new life.

Small background about the GS and how I get it ,

The very my own GS I’ve got since end of summer last year, the funny fact is that this motorcycle is the same one that I have first ride after getting my license in 2010. I’ve get it from one of my best friend since kid’s days. He bought it in 2009. Below some pic. Of the day that I was taking GS to his new home.

As you can see the it was not in a very good shape, nothing strange the life verifies my mate plans, and the GS was in the basement not touched for about a year, in the home repair environment (dust form the wood, metal, cutting etc.). few days before we try to start the GS but only a jump starter help with it – YEAP battery dead. So I took a new battery from local store and next day I was going with my better half to take the GS! Excitement level 1000+, the first ride about 1 mile then about 20 miles to home. The small legal problem was that it was not having approval form the government (in Poland you need once per year go to the verification station to the the road legal approval), but I was having insurance, so I was feeling ok. for this. After this I manage to the the approval, clean GS and start the season.



Few things about the GS itself:
It is a SUZUKI two stroke engine, from 1993, made in Japan.
I do not know the story before but looking at It I know that original paint was red. Now is Black Matte.
It has done about 94 000 km and counting.

Unfortunately, just by having GS 4 weeks, I’ve got my first accident ☹, I was having a very short trip to the shop, during some home repair work, and when I was back home on a round abound some dum&^%# forced priority and the only decision I could do was or hit him, or fall over to the left. Decision was quick to fall over. Lucky that the speed was low, and that I’ve only get some scratches on the skin. For the GS, the clutch lever was broken, head lamp, fuel tank, speedometer, tachometer body, trunk gets bends and scratches ☹☹☹. I’ve manage to get back home riding so no damage to the chassis – this was good info. And yeah, this guy just run after I hit the ground. I didn’t get the license plate number, nor anybody around. This give me the lesson that even for the short trip EVEN 2 KM you need to get the clothes, not short and t-shirt.

The clutch lever was chip – about 4$ so I bought it next week and get the GS, available for a ride so from that time I’ve only enjoy the ride did some oil’s and filter change, but the rest wasn’t touched till end of the season. I end the season doing about 2000km in 3 months so I’m calling this a good start.

So as the winter come, and finally I’ve got some time I start the project the NEW LIFE for GS,
The idea is simple,

Repair anything that need repair,
Do the paint work,
Make a new odometer-speedometer body ,

Here are some pic of GS as it is looking right now (please do not look for the anything around – this is my basement and everything I have for the garden, tools etc. are there.








I start by disassembly the speedometer and odometer body – this will be interesting as it is already custom made by my friend �� this will come with the pictures.
First take the two mounting plate nuts 13mm off,



Next take out additional two screw (should be three but the left one was lost with the crash I think ) that are holding the plastic body to the mounting plate, I use this flexible extension for the bits – it is really helping with some screws that are in the tight area,




Next I take out the speedometer and odometer body – and here is the surprise both are custom, made from the camping cup, the original plastic body was expensive so my friend made them (still wondering how he get this idea ), disassembly was easy – they were fixed to the position by the hot glue.



Here is pic after disassembly the cup’s – plastic body that was under the cups's, metal mounting plate and even the gaskets are in terrible condition ☹



The next step was to unscrew the speedometer and odometer cables – simply, same both sides



Then take the speedometer restart roller (I do not know how this could be spell in English – this is the roller that you can use to “zero” the millage to count the fuel tank), it was simply also to disassembly – hold by one small screw inside.



After taking this out and take out the light bulb – the speedometer was take out from the body,

Next odometer – this will be tricky as there is custom made change gear display – so the only way to do this was to disassembly the protective glass from the top, unscrew the 2 mount screw from the back body, and push the gear display to the body, after this odometer easy to take out from the body,
The only thing that left was disassembly the light from the mounting plate, easy and done,





Gaskets I need new, or make new



So, next it to verify all the things that I have and get new part or fix current. For now this is all of I have done,





btw. I love to see stuff like this - NSM JAPAN



If you have any ideas that could help, please let me know I’m a beginner in this but this is I think the best start for any project that I could have. Still do not know what are the next step – hope the steps will come soon The goal is to do all the work before the start of the season.

Any one more thing – I think I write to much – will make a correction on this next time
Cheers Piotr !

Try using http://tinypic.com/, they have always been pretty good for hosting images.

tarbellb said:

Try using http://tinypic.com/, they have always been pretty good for hosting images.

Click to expand...

Thanks ! should work right now

Always good to resuscitate something. Sometimes the item is too-far gone to financially be worth the time & $ or zlotys.

You mentioned in the first post that it is a "two-stroke" ("It is a SUZUKI two stroke engine...") which I believe is incorrect. It is a four-stroke, complete with valves and other stuff. I had a 2007 GS500 I got as a basket case, I paid a case of beer for it. I didn't bother to get it running, I kept some parts I could use elsewhere, and parted the rest out, pretty-quickly.

Make sure that your engine has fresh oil, and that you change it frequently. If you have starting and running problems, drain the float bowls, change the gas filter, if it doesn't have one, get one. These are good ones, rebuildable:
http://cdn1.bikebandit-images.com/product_images/em/450/emgo-universal-fuel-filter.jpg

If you have leaking front forks, I suggest using only OEM fork seals. Many people use automatic transmission fluid for fork oil, probably much cheaper than fork oil and readily available. Oil from a leaking fork can contaminate your front brake caliper pads, leaving you with little for braking. If the fork downtubes are rusted along the area wiped by the seals, you need replacement tubes, which are usually very expensive OEM parts. Putting new fork seals on rusted downtubes will kill your fork seals very quickly. These people can make tubes for you and they ship to Europe: http://franksforks.com/

Good luck with the project.

driftpin said:

You mentioned in the first post that it is a "two-stroke" ("It is a SUZUKI two stroke engine...") which I believe is incorrect. It is a four-stroke, complete with valves and other stuff.

Click to expand...

You are correct driftpin. The GS series were 4 stroke. It was the GT series that was 2 stroke. Back in the day I drove both, and they were smooth runners.

A great bargain, the Suzuki 500 Titan parallel-twin, two-stroke, not ****, but very reliable, and reasonably-priced. I think Gordon Jennings of 'Cycle' magazine raced one in AMA roadracing, they could be ported to significantly increase the HP when used w/correct expansion chambers exhausts, and jetted correctly.

The Kawasaki, Yamaha and Suzuki two-stroke road bikes of the 1970's were 'giant-killers,' much-despised by the British vertical-twin riders, and the H-D contingent, but they had AMF to worry-about.

I had a Kawasaki Mach III 500 cc two-stroke triple cyl, and my roommate had a brand new, first year of the 1,000 CC Harley-Davidson Sportster, and there was no-way that he could keep up with me in any contest of acceleration.

My favorite story of my Mach III:
I was cruising down I-95 in Ft. Lauderdale, back in the mid-1970's. Up ahead I saw a double-file train of motorcyclists. There were a bunch of them, and as I got closer, I saw it was a 'run' of the notorious Outlaws motorcycle gang. They were always in the news for getting in fights, being arrested, and living-up to their name. They had a clubhouse just-south of Ft. Lauderdale where they had a firing range, and often you could hear them using it as you went by. Sometimes it was "braaaap-braaap" as they squeezed off what sounded like automatic weapons fire. They were a thorn in the side of local law enforcement.

So, back to I-95 and the Outlaws formation. I estimate there were about two dozen, some with their women behind them, all with the death's head and crossed pistons emblem, and the Florida rocker. It was a cool, overcast day, perfect weather for air-cooled bikes, dense, cool air.

As I caught-up to them, they were holding formation. They were going slower than I was, so I decided to pass them on the left in a hurry. As I caught the rear of the group, I kicked the 500 cc triple cyl into 4th gear, wacked the throttle open, and went past them in a hurry.

Now, you young whippersnappers probably don't have the experience of running a two-stroke hard, especially a street bike considered to be a performance king of the day. When you open the throttle, the bike starts to combust vigorously, and it leaves a trail of two-stroke oil and gas fumes in its wake. It's visible, and it hangs in the air a bit. So I'm passing all these formation-riding Outlaws, and here-comes this mosquito-fogger of a 'ring-ding' bike, running hard past them, and in its wake, a cloud of two-stroke exhaust, enveloping the entire formation in the cloud. You can just imagine, as two-dozen Outlaws have their reverie disturbed by this cloud of oil fumes, what they are yelling-about. "We're the Outlaws! Who does he think he is? (hack-cough cough)

In the Dark Ages, the champion of the castle goes through the portcullis, across the drawbridge and moat, and out to combat the threatening force's champion in a "1-on-1" contest. The Outlaws, having been disrespected by the 'ring-ding' two-stroke rider, now dispatch their champion out to catch-up to the rapidly-departing rider of the two-stroke.

I saw in my rear-view mirror that one of the group had started in pursuit as I passed the front of the formation. I didn't wait around to hear if he wanted to discuss the paint-job on my Kawasaki, the jetting of its carbs, or the operator skill I displayed as I rode past them. No, I screwed that throttle cable open as-far as it would go, like Commander Cody says, "'till there ain't no-more" and I kept it there. The Harley-Davidson chasing me down, I am sure was working very hard to close the gap, but the effort was about as-useless as trying to keep the POTUS from sending out tweets against his detractors at 3 a.m. in the dark night.

I chanced a glance over my shoulder after a few seconds, and all I saw was an expanding cloud of two-stroke haze, from the rear of my bike, extending down the interstate, and the entire Outlaws contingent enveloped in it. By now, the guy chasing me had given-up on his useless effort, and had slacked-off in his pursuit, though he was far in-front of his comrades. I didn't bother waiting for them to catch-up to me, to ask about my machine's performance, I kept on it until I turned off at my exit, and was out of their line-of-vision. I can just imagine their conversations at their destination:
"Wow, did you see the acceleration of that bike, I gotta get me one 'a those!"

"Gosh, he sure was a skilled rider, I'd like to shake his hand, and get some riding tips from him."

And from the ladies, "he sure was cute!"

Ah, to be in your twenties and on a two-stroke triple, that was riding!

Yes !! thanks for correction kind of typo !
for the rest I have one of the best friends that is also a moto maniac but he is since young years, currently about 19 years so he helped a lot with parts filter and so on. I also have in my mind that if you buy car or a motorcycle you need to do first the "basic" service, oil, filters, battery, forks etc. so it was done

btw. Driftpin ! - really Nice story hope to get such a story in future

Small update: Tomorrow I should have 2 new dampers for odo and tachometers so one step closer. Funny thing that buying them from the OEM service was cheaper than try to get them from internet. ng:

Piotr

Two day ago I was able to make some progress on GS as new part arrived

This time it was a front brake disc, a previous was way above the life time, lot of loose on rivets so need to be replaced,

I was looking long time for the brake disc as it is expensive, original cost around 450$, alternative around 150$. Finally looking on different bikes that have the same parameters break discs i found one with kind of "strange" shape from Lucas TRW for 90$ so I call it a very good deal.

First I take out the two screw that are holding caliper to the damper



then it was time for one bolt that is clamping the axle



next bolt that is holding hook for line of speedometer gear (the small one)



then come the axle,



after removing the axle, wheel is out, and next to go 5 bolt that are holding break disc to the the wheel - these were though ones as there is a thread lock glue on the thread - but good and long wrench and they will go easy



Old disc removed !!!



New disc in place



First fit to the GS',



everything is OK ! I was a little worried about this because of the price of the brake disc, the store price of the Lucas TRW is around 250$ - the disc I bough was 90$ but it was taken from the liquidation of the another store - as above good deal for me

Still need to replace the pads but this will come soon, I also want to look and verify the caliper is everything OK. there and clean it.

Till next time !

Long time since last update, still wondering why I didn't post anything where I'm really enjoying GJ ,
Nevertheless quick update for GS and for the Plan,
after last update there was a long time in business trips etc. so when finally the weather was pushing me to get GS done, I've manage to done it within 2 day. really nice summer manage to do about 3000km this year. now it is time one more time put the GS in to the basement (garage still will not happen this year ) but fingers crossed for next year ,
the original plan was to repaint GS with Harley gray color, but as above, no time for that better to drive then to wait until paint will dry and now I have an air compressor so GS will be first to learn how to paint

almost full year without problems (main fuel line is not working properly but only on long fast rides [above 150km/h] probably something with the fuel splitter).

I didn't make a new "cup-housings" for odo and tacho but the stainless cup are waiting for that,

I should be able to make this thread alive ! sure I can, but it will be not only about GS, but also about other stuff that I do, maybe someone will find something interesting here !

till next time (soon )

The GS500 was a good little bike.

Hi Stuart

it still is good I have a lot of fun with it

Bit of an update:

Need to change tires for winter once,
2 cars, no summer/winter wheels - need to change on both tires,

I thought that I can make one trip so decide to take wheels and tires from wife car and go with mine, so it was a good occasion to check car stands that I have from about 3 months.

sorry for bad pic, it was already late and dark,





easy job, as previously working on the car I did manage to clean the wheels, and apply some copper grease for easy assembly,

one point taken, I need a new jack... the old one do not lift the car high enough to put a stand with a core, so the car is on the one piece (foot?) from the stands, and a piece of wood between floor and stand to do not damage anything

today I'm going to change the tires so hopefully will have both cars also ready today