92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-10-24-12
- Thread starter ben2go
- Start date
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
I know how to weld.It was part of two different courses I took in school,industrial tech in high school and industrial maintenance in trade school.Plus I have done some welding off and on over the years at jobs and using friends equipment.None of my friends are near by any more.They got smart and left this place.But yeah,I could always learn more.Never wanna stop learning.If I do, I might kill over.
Erskine said:
I know how to weld.It was part of two different courses I took in school,industrial tech in high school and industrial maintenance in trade school.Plus I have done some welding off and on over the years at jobs and using friends equipment.None of my friends are near by any more.They got smart and left this place.But yeah,I could always learn more.Never wanna stop learning.If I do, I might kill over.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
I get that and it's usually my way of thinking.I have 90% of everything I need to build the trike.It's not something I would ride much,if at all.I really want to build one for the experience, and to prove to a few people I know that I can do it.I still may build just so I can prove those few wrong plus have a one of a kind trike.Maybe hang onto it for my golden years when my back and knees won't let me ride a two wheeler.
I have a lot of people asking me about tires, where I buy mine, and have them installed.Well, I buy my tires online, and I spoon them on myself,or I get a friend to do it with his tire changer.I can balance tires, but I let my friend do it, because he is faster at it than me.So all this got me to thinking.I need some steady supplemental income.I think I may invest in one of those cheap moto tire changers(like the old HF set up) and a quality balancer and make some extra cash.I've used the HF tire charger without any issues,plus I can always hand spoon them without much trouble at all.So I am seriously considering getting into the tire biz.It would go along way toward helping me fund my projects.
peteGS said:Here's a tip for you... don't rely on the whims of a woman to determine whether you do or don't do something bike related
If you want to do the trike, just do it...
I get that and it's usually my way of thinking.I have 90% of everything I need to build the trike.It's not something I would ride much,if at all.I really want to build one for the experience, and to prove to a few people I know that I can do it.I still may build just so I can prove those few wrong plus have a one of a kind trike.Maybe hang onto it for my golden years when my back and knees won't let me ride a two wheeler.
I have a lot of people asking me about tires, where I buy mine, and have them installed.Well, I buy my tires online, and I spoon them on myself,or I get a friend to do it with his tire changer.I can balance tires, but I let my friend do it, because he is faster at it than me.So all this got me to thinking.I need some steady supplemental income.I think I may invest in one of those cheap moto tire changers(like the old HF set up) and a quality balancer and make some extra cash.I've used the HF tire charger without any issues,plus I can always hand spoon them without much trouble at all.So I am seriously considering getting into the tire biz.It would go along way toward helping me fund my projects.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
It's been cold and rainy most of January so I did some parts sourcing.I got and early style tank and a late style tank for $185.Both need some tlc but I think I can get them straightened up.I am also looking into buying a front end upgrade.A friend has a complete 1988 Katana front end.I have a set of adapter spacers, or I can do a stem swap.I will have to wait and see how things fit together before I decide if I want to do a stem swap.I did the stem swap on my black GS, and it lowers the top triple about 1.2 inches.Since this is going to be a touring bike,I may use the spacers to keep the upper triple up higher for a better riding position.May be able to eliminate the need for bar risers.
Here's the cost break down so far.
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
$92.50 Fuel tank
_______________________________________________
$507.53 Total
I think I'll come in under $1000 for the bike.My add ons will of course run up the cost a little.Still a good price for a bike with 1865 miles on it.
It's been cold and rainy most of January so I did some parts sourcing.I got and early style tank and a late style tank for $185.Both need some tlc but I think I can get them straightened up.I am also looking into buying a front end upgrade.A friend has a complete 1988 Katana front end.I have a set of adapter spacers, or I can do a stem swap.I will have to wait and see how things fit together before I decide if I want to do a stem swap.I did the stem swap on my black GS, and it lowers the top triple about 1.2 inches.Since this is going to be a touring bike,I may use the spacers to keep the upper triple up higher for a better riding position.May be able to eliminate the need for bar risers.
Here's the cost break down so far.
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
$92.50 Fuel tank
_______________________________________________
$507.53 Total
I think I'll come in under $1000 for the bike.My add ons will of course run up the cost a little.Still a good price for a bike with 1865 miles on it.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
Fuel tank have arrived.I got a new used starter clutch housing.I also picked up a really nice Katana front end,GS header,and another tanks for the trike project.I am getting worked up.I hope to get some pics and work posted next week.
Here's the cost break down so 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
$92.50 Fuel tank
$10 starter clutch
_________________
$517.53 Total
Fuel tank have arrived.I got a new used starter clutch housing.I also picked up a really nice Katana front end,GS header,and another tanks for the trike project.I am getting worked up.I hope to get some pics and work posted next week.
Here's the cost break down so 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
$92.50 Fuel tank
$10 starter clutch
_________________
$517.53 Total
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
I don't remember if I showed this earlier in the thread,So I am posting it again.
I will be pulling the front end and making some adjustments.Then I will turn the motorcycle around in the building so I can work on the rear end.I have the original swing arm from my black 89 GS.It will make a good replacement.I hope I have another set of adjusters and end plates.
I plan to adjust the mistake I made on the forks,get the gauges sorted out,install the new front wheel,turn the bike around,install the replacement swing arm,and new rear wheel.
I gotta wait the rain out over the weekend before I can work on the bike again.Roof leaks and I have dirt floors that get mushy when it rains.
I don't remember if I showed this earlier in the thread,So I am posting it again.
I will be pulling the front end and making some adjustments.Then I will turn the motorcycle around in the building so I can work on the rear end.I have the original swing arm from my black 89 GS.It will make a good replacement.I hope I have another set of adjusters and end plates.
I plan to adjust the mistake I made on the forks,get the gauges sorted out,install the new front wheel,turn the bike around,install the replacement swing arm,and new rear wheel.
I gotta wait the rain out over the weekend before I can work on the bike again.Roof leaks and I have dirt floors that get mushy when it rains.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
Ok guys,I didn't get any work done this week. :-[ Weather has been crappy, plus I had appointments and was in the hospital tuesday and friday.I haven't been up to doing to much. :'( I have more doctors appointments next week and the threat of snow has been mention in the news.Luckily we are supposed to hit another overly warm period end of next week.I hope to have all this hospital and doctor stuff outta the way so I can work,if I feel up to it.
Parts came in so I have more to add to the tally.
$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
$92.50 Fuel tank
$10 starter clutch
$24 Mikuni Jets for rejetting
___________________________
$541.53
I'm still looking at $200 in parts plus paint and titling in my name and state.I have some parts that I will be selling off to help offset the cost,so I should still come in around or under $1000 on this build.I don't know if I'll have enough wiggle room to make or buy accessories and still be able to sell it and break even if I have to.
On another note,I have been designing and parts hoarding for the trike build.I picked up a complete Katana front end for it.I need to find a 98+ Katana 3.5 inch front wheel,or better yet,a DL1000 VStrom 19 inch front wheel.
Ok guys,I didn't get any work done this week. :-[ Weather has been crappy, plus I had appointments and was in the hospital tuesday and friday.I haven't been up to doing to much. :'( I have more doctors appointments next week and the threat of snow has been mention in the news.Luckily we are supposed to hit another overly warm period end of next week.I hope to have all this hospital and doctor stuff outta the way so I can work,if I feel up to it.
Parts came in so I have more to add to the tally.
$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
$92.50 Fuel tank
$10 starter clutch
$24 Mikuni Jets for rejetting
___________________________
$541.53
I'm still looking at $200 in parts plus paint and titling in my name and state.I have some parts that I will be selling off to help offset the cost,so I should still come in around or under $1000 on this build.I don't know if I'll have enough wiggle room to make or buy accessories and still be able to sell it and break even if I have to.
On another note,I have been designing and parts hoarding for the trike build.I picked up a complete Katana front end for it.I need to find a 98+ Katana 3.5 inch front wheel,or better yet,a DL1000 VStrom 19 inch front wheel.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
Monday my doctor put me on Loratadine and Prednisone for an allergic reaction I had.Yesterday,we had crappy weather.Today it got warm and I went to work.Prednisone amps me up like no other.Glad I only have to take it for two weeks.I could see me getting hooked on this stuff.
Anyway,things took a temporary turn in my plans.My black 89 GS came down with some serious head shake.So I transplanted the original GS front end back onto it off of project "Lite Tourer".As soon as,I can figure out where the problem is,I will make the needed repairs,and get back on project "Lite Tourer".
I was under the gun today,so I didn't get any pics.Tomorrow,I hope to roll it out and get a few pics.I got it back on it's wheels right at dark.BTW,my black 89 GS is going naked until I get the head shake problem sorted out.I think it's a bad lower stem bearing or a worn fork bushing.
Monday my doctor put me on Loratadine and Prednisone for an allergic reaction I had.Yesterday,we had crappy weather.Today it got warm and I went to work.Prednisone amps me up like no other.Glad I only have to take it for two weeks.I could see me getting hooked on this stuff.
Anyway,things took a temporary turn in my plans.My black 89 GS came down with some serious head shake.So I transplanted the original GS front end back onto it off of project "Lite Tourer".As soon as,I can figure out where the problem is,I will make the needed repairs,and get back on project "Lite Tourer".
I was under the gun today,so I didn't get any pics.Tomorrow,I hope to roll it out and get a few pics.I got it back on it's wheels right at dark.BTW,my black 89 GS is going naked until I get the head shake problem sorted out.I think it's a bad lower stem bearing or a worn fork bushing.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
That would be correct.As soon as I figure out where the issue is and fix it,it's going back on my black bike.Project "Lite Tourer" will basically be a stock GS with some accessories.I don't want a loud bike for long distance riding,so the air box and exhaust will stay intact but may get a little paint.
We are having a good bit of rain today.If it clears out after lunch,I want to get some pics to post.I hope to have the front end back together by night fall.
Big Rich said:
That would be correct.As soon as I figure out where the issue is and fix it,it's going back on my black bike.Project "Lite Tourer" will basically be a stock GS with some accessories.I don't want a loud bike for long distance riding,so the air box and exhaust will stay intact but may get a little paint.
We are having a good bit of rain today.If it clears out after lunch,I want to get some pics to post.I hope to have the front end back together by night fall.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
I got the front end back on project "Lite Tourer".Didn't get any pics tho.I did order some parts this evening so it's time for a cash layout update.
$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
$92.50 Fuel tank
$10 starter clutch
$24 Mikuni Jets for rejetting
$12 2 x Float Bowl Gaskets
$18 Rear Brake Caliper Rebuild Kit Read on to find out why this changed.
$6 Alternator Cover Gasket
$17 2 x Float Needle & Seat
$5 Oil Filter
$8.50 In Shipping Costs
__________________________________________
$590.03
I still have a couple parts orders to make and a few local parts round ups to do.Then I can get down to completing the bike for testing.Once testing and tuning is done,it's time for stripping and painting.Pretty much going to be back close to stock but not quite.You'll just have ta wait n see.
I couldn't find carb rebuild kits in stock, so I ordered new needle and seats along with bowl gaskets.I am planning to buy a metric master O ring kit.What will hold up better to the blended fuels,viton or neoprene?According to McMaster Carr,neither is suited for use with alcohol,but both are rated for gasoline.Now that's a but scratcher.
I got the front end back on project "Lite Tourer".Didn't get any pics tho.I did order some parts this evening so it's time for a cash layout update.
$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
$92.50 Fuel tank
$10 starter clutch
$24 Mikuni Jets for rejetting
$12 2 x Float Bowl Gaskets
$6 Alternator Cover Gasket
$17 2 x Float Needle & Seat
$5 Oil Filter
$8.50 In Shipping Costs
__________________________________________
$590.03
I still have a couple parts orders to make and a few local parts round ups to do.Then I can get down to completing the bike for testing.Once testing and tuning is done,it's time for stripping and painting.Pretty much going to be back close to stock but not quite.You'll just have ta wait n see.
I couldn't find carb rebuild kits in stock, so I ordered new needle and seats along with bowl gaskets.I am planning to buy a metric master O ring kit.What will hold up better to the blended fuels,viton or neoprene?According to McMaster Carr,neither is suited for use with alcohol,but both are rated for gasoline.Now that's a but scratcher.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
Thanks Rich.I thought zuk used plain rubber.They don't last long in my carbs.A few years at most.
UPDATE
I have decided to use the rear brake system off my 89 on projet "Lite Tourer".The system was rebuilt built about three years ago and is in great shape less than 3000 miles on it.I am planning to rebuild Lite Tourer's brake system for my 89 and add some custom touches.
So I now only have $590.03 total.
Big Rich said:
Thanks Rich.I thought zuk used plain rubber.They don't last long in my carbs.A few years at most.
UPDATE
I have decided to use the rear brake system off my 89 on projet "Lite Tourer".The system was rebuilt built about three years ago and is in great shape less than 3000 miles on it.I am planning to rebuild Lite Tourer's brake system for my 89 and add some custom touches.
So I now only have $590.03 total.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition
Dropped another order off.
$590.03
$1.99 alt/gen rotor bolt
$8.46 clutch push rod <-----Funny story maybe I will tell ya'll some time.It involves a frozen chain and me pushing the bike. ;D
$5.02 clutch push rod seal
$24.15 both side cover emblems
$22.76 04-07 Honda CRF250X petcock <---- This mod takes care of that stupid stock vacuum petcock.
$12.00 shipping costs
_______________________________________
$664.41 Total invested, if you wanna call it an investment.
I have found that if I write down everything I need,visit the websites I trust,I can divvy up everything between a few of them and come out cheaper.It's a bit of work, but hey, I like looking at parts as much as riding.
Ok,funny story mentioned above.On the GS twins,the clutch rod runs through the motor just in front of the drive chain.I pushed this bike 250 yards with a partially seized chain and managed to break the clutch push rod.I should have removed the chain.I knew better than to trust an unknown weathered chain.I'd a dumb ass at times.
Here is how things are supposed to be.I don't have a pic of the damage I did to Lite Tourer.
I also did this becaus of the chain.I am such a dumb ass at times.
Dropped another order off.
$590.03
$1.99 alt/gen rotor bolt
$8.46 clutch push rod <-----Funny story maybe I will tell ya'll some time.It involves a frozen chain and me pushing the bike. ;D
$5.02 clutch push rod seal
$24.15 both side cover emblems
$22.76 04-07 Honda CRF250X petcock <---- This mod takes care of that stupid stock vacuum petcock.
$12.00 shipping costs
_______________________________________
$664.41 Total invested, if you wanna call it an investment.
I have found that if I write down everything I need,visit the websites I trust,I can divvy up everything between a few of them and come out cheaper.It's a bit of work, but hey, I like looking at parts as much as riding.
Ok,funny story mentioned above.On the GS twins,the clutch rod runs through the motor just in front of the drive chain.I pushed this bike 250 yards with a partially seized chain and managed to break the clutch push rod.I should have removed the chain.I knew better than to trust an unknown weathered chain.I'd a dumb ass at times.
Here is how things are supposed to be.I don't have a pic of the damage I did to Lite Tourer.
I also did this becaus of the chain.I am such a dumb ass at times.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-3-18-12
Here's an update on what I have done this week besides order parts.
A friend of mine is getting rid of all his GS500 and motorcycle related stuff.So I have picked up a few things.
I got everything to build a new used starter clutch since I robbed Lite Tourer of it's original one.I assembled it and got it ready to install.
I got the brake rotor and hub cover mounted to the new used front wheel.
Brought my friends tire changing and balancing equipment.
I kind of been keeping this on the down low.My black 89GS has a Katana 750 front end with CBR600F1/2 clip ons.The bars hit the bigger 05 tank.So I decided to cut up a set of stock GS handle bars and make new hi rise bars for my clip ons.They are adjustable fore and aft,plus they can be widened from their current position.I am still waiting on parts to rebuild my front brakes and do some maintenance before I can test them out.All the stock wiring and cables work.I was surprised.
Here's an update on what I have done this week besides order parts.
A friend of mine is getting rid of all his GS500 and motorcycle related stuff.So I have picked up a few things.
I got everything to build a new used starter clutch since I robbed Lite Tourer of it's original one.I assembled it and got it ready to install.
I got the brake rotor and hub cover mounted to the new used front wheel.
Brought my friends tire changing and balancing equipment.
I kind of been keeping this on the down low.My black 89GS has a Katana 750 front end with CBR600F1/2 clip ons.The bars hit the bigger 05 tank.So I decided to cut up a set of stock GS handle bars and make new hi rise bars for my clip ons.They are adjustable fore and aft,plus they can be widened from their current position.I am still waiting on parts to rebuild my front brakes and do some maintenance before I can test them out.All the stock wiring and cables work.I was surprised.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-3-18-12
I had to get her on her wheels and rolling ASAP.It's time to drag out the grass chewers.
I got the front end together and installed the Smurf wheel mentioned previously.Then I traded spots with the grass chewer.Here she is in here new work spot,next to the poor purple GS5.You're not crazy.Those bars are tweaked.I am debating on what bars I want to run.Probably some cheapos with a bit more height and pull back.
I am still waiting on parts that I have ordered.Only one batch has come in so far.Ron Ayers is showing that the parts are coming from a warehouse.Essentially,they are back ordered.
I had to get her on her wheels and rolling ASAP.It's time to drag out the grass chewers.
I got the front end together and installed the Smurf wheel mentioned previously.Then I traded spots with the grass chewer.Here she is in here new work spot,next to the poor purple GS5.You're not crazy.Those bars are tweaked.I am debating on what bars I want to run.Probably some cheapos with a bit more height and pull back.
I am still waiting on parts that I have ordered.Only one batch has come in so far.Ron Ayers is showing that the parts are coming from a warehouse.Essentially,they are back ordered.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-3-18-12
YES!
I just got an email from Ron Ayers.My order shipped from Greenville,NC.That's fairly close to me.Should have my parts here Sat or Mon.It's time to get started rebuilding some parts for project Lite Tourer.
YES!
I just got an email from Ron Ayers.My order shipped from Greenville,NC.That's fairly close to me.Should have my parts here Sat or Mon.It's time to get started rebuilding some parts for project Lite Tourer.
ben2go
Two Wheel Projectile
Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-3-22-12
AWESOME!
Seems Ron Ayers sent my parts overnight or 2nd day.I got the email that they had been posted to ship late yesterday afternoon and they arrived this morning before 11am.Now,I just have to wait out this rain. :-\
AWESOME!
Seems Ron Ayers sent my parts overnight or 2nd day.I got the email that they had been posted to ship late yesterday afternoon and they arrived this morning before 11am.Now,I just have to wait out this rain. :-\
