92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-10-24-12

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Small but big step forward update.

I got all this for $60
Good set of wheels with track tires.Bearings are silky smooth and tight.
bluewheels3.jpg


Unused POR-15 tank liner kit.
por15tankkit.jpg


Right side case cover,ignition cover,good regulator rectifier,and starter gear.The case cover and ignition cover are for the purple bikes engine.
mscparts.jpg


Still needed
set of forks
rebuild kits for front and rear master cylinders and calipers
clutch push rod
starter clutch rebuild kit
front and rear brake pads
battery
fuel tank
lock set
handle bars
tires
stator cover gasket
rotor bolt

My running total on this bike is

$150 1992 Suzuki GS500E WRECKED
$200 Title Service
$60 misc. parts
_______________
$410 Total
-$40 sold in misc parts
_______________
$360 Grand Total as of 11-20-11


I'm shooting for $800 with an absolute max of $1000.If I can keep it under $800,I'll have some wiggle room for goodies like case savers/guards,windscreen,bark busters,and luggage with racks.Luggage and racks will be home brew of course.
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

I decided on using the forks from my black 89 GS500 resto mod.They were rebuilt by me and then I decided to go with a 95 Katana 750 front end.I may still go with a Katana front end,but for now I am going to keep it cheap.I put the purple bike's warped front wheel on long enough to load into my trailer,and get to the dmv to get my title.

Here's how she sits for now.Anyone notice what I did wrong when I put the forks on?This is temporary until I get my title.Then she's getting stripped for paint and final build up.
11-26-11.jpg
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Ummmmm...... you haven't completed the "outer fender" mod?

:D
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Big Rich said:
Ummmmm...... you haven't completed the "outer fender" mod?

:D
Click to expand...

;D Nope.I was in a hurry and didn't turn the slider around.It went together, and the front wheel rolls, so it's staying until I get my paper work sorted for a title.After that,it's tear down for paint and reassembly.Got a bunch of parts coming.So far it looks like I will be under $800 for the completed bike.If I break down and buy a new used fuel tank I think I can stay under $1000.

Anyone have a straight GS500 fuel tank to donate to a good cause?
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

A tiny,almost not worth mentioning, update.I finally got a front axle that is dead nuts straight.Whooo freakin hoooo!These are the second thing to get bent on a GS500 just after the forks. ::)

$13.84 doesn't buy a lot but this was on the cheaper side.
11-30-11.jpg


Cost so far,previously stated $360 + $13.84 = $373.84 and rising as of 11-30-11.
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Nudder small up'em date.I received my new used headlight brackets this morning.The substitute mail lady looked a little scared when I opened the door.I looked a little rough this morning.Couldn't help but giggle as she dashed across my front yard back to her mail jeep.LOL

12-3-11.jpg



Cost break down thus far.
$150 Bike Purchase
$175 titling Service
$60 F/R Wheels,Tires,Regulator Rectifier,Starter Gear
$13.84 Front Axle Bolt With Spacers
$16.19 Headlight Brackets
_______________________________________________
$415.03 Total

A little higher at this point than I would like but manageable I think.
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Everything is put to bed until after New Years.I have a few parts coming for the project.Winter has been very mild here so far but January is usually when we start getting hit with ice and snow.

In the mean time,I am trying to decide on paint.Should I just paint things back original colors or change it to something I like.Keep in mind that I plan to sell this bike after a couple road trips.Usually,restored all stock GS500 brings more money than a customized GS500.What to do what to do?My current color combo that I like is black frame,engine,swing arm,triples,bars,and fork lowers with the original red body work and red wheels.What say ye?If I was planning to keep the bike long term,I would do black frame,engine,swing arm,triples,bars,and fork lowers with a darker blue for body work and wheels.I'm not into flashy bikes to ride.if this was going to be my prize bike,it be all flash and class.
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Ben, did you see Tombstones GS? He used a metal flake red paint on the tins - looks pretty good IMO. Might be worth looking into.
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Big Rich said:
Ben, did you see Tombstones GS? He used a metal flake red paint on the tins - looks pretty good IMO. Might be worth looking into.
Click to expand...

Hey Rich.I surely haven't seen it.I will try a search and see what comes up.I may have to look into something like that.I thought about using Duplicolor's paint shop kit for cars.
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

I couldn't find his GS.Can you point me in the right direction?
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Here ya go buddy:

http://gstwins.com/gsboard/index.php?topic=58225.0
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Big Rich said:
Here ya go buddy:

http://gstwins.com/gsboard/index.php?topic=58225.0
Click to expand...

Thanks Rich.I was thinking it was on this forum. ::)
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Turn of events,maybe for the better.I dunno,but I gotta get this bike done before spring.My uncle bought himself a motorcycle.He's never owned one in his life.His neighbor talked him into it.His wife tried to talk him out of it.Now his son,my cousin,wants to buy a small bike to keep up with him so he won't be out riding alone.They do a lot of stuff together so it could work.Anyway,my family had our Christmas gathering this past Friday evening.I was talking to my cousin,and showed strong interest in want to buy the bike, in this thread, when I am finished with it.He has saw my black 89 GS500.When I told him it was the same bike, but going to be restored,instead of modified,his eyes lit up like Rudolph's nose on Christmas.So I might not get a chance to ride it,except for the shake down during test and tune.He asked how much I would have to have for it, and I said," $1600 to $1800 ready to go,needs nothing but paper work."He got a big sinister grin,looked at his wife,and she turned snow white.I just kind of laughed.I'll just have to wait and see what happens at spring.They are expecting their second child.That may crush the deal.It gives me a reason to light the fires.

BTW,I started doing inventory this past week.I'm going to ditch the purple bike rebuild and go straight into the trike build after I finish this project.Looks like I have nearly everything I need to mock up the trike. 8)
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Haha that's good stuff, more GS owners to the fold :D

I'm definitely looking forward to the trike too...
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

I am looking forward to the trike project,too.I'm debating on a cheap flux core welder or farming it out.I don't have any buddies that own a welder any more so it could get pricy at hourly shop rates of $75+ per hour.I'll think on it some more.There's really not going to be much welding.I could rent a welder and do it all In less than and hour.That would be about $75 for the rental.What to do what to do?
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

ben2go said:
I am looking forward to the trike project,too.I'm debating on a cheap flux core welder or farming it out.I don't have any buddies that own a welder any more so it could get pricy at hourly shop rates of $75+ per hour.I'll think on it some more.There's really not going to be much welding.I could rent a welder and do it all In less than and hour.That would be about $75 for the rental.What to do what to do?
Click to expand...


Sounds to me like if you were able to get a suitable welder for something like $150 then you can take your time with it without rushing to get it back to the rental place in time or worrying about if it takes a professional welder longer than an hour to do the job... plus you can then weld other stuff as it comes along ;)
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

peteGS said:
Sounds to me like if you were able to get a suitable welder for something like $150 then you can take your time with it without rushing to get it back to the rental place in time or worrying about if it takes a professional welder longer than an hour to do the job... plus you can then weld other stuff as it comes along ;)
Click to expand...

I'm looking and keeping my options open.I plan to get cracking on the trike come spring,April.
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

Awww man that means I have to be patient! I'm not good at that... :p
 
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition

peteGS said:
Awww man that means I have to be patient! I'm not good at that... :p
Click to expand...

Ohhhh,you might hate me after this one.My girl said she wasn't interested in riding with me,sooooooo I might not build the trike.I'm going to wait and see.I may build it and tour the world alone.OK,maybe hook up, and ride with some peeps from the forums, from time to time. ;D
 
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