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

[ben2go]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-3-22-12

Got started on the mock up phase again.Gotta good bit done today and got burnt all to hell.Thank you Mr. Sunshine.


I removed the exhaust late in the evening yesterday.This opens up the right side for rear brake and suspension removal.Gotta get all this stuff cleared out and make way for the new used swing arm,wheel,and soon rear brake system.

Bye bye,see you parts later.

So long old bent swing arm.Maybe I should combine the old swing arm and the new used one,and stretch this whore out.

Nooooooo!She looks purdy as is with Smurf wheels.Them damn things are gonna get me spotted all over the world.

Just one little issue left to sort out,well two.

First,the rear sub frame is slightly tweaked just behind the seat latch.I'll fix that before tear down for paint.That sucky red brick is gonna get flipped over, to follow the body lines better.Hey,100% free mod.

Second little issue.Apparently the 89 GS500 with factory clip ons front brake hose is a couple inches shorter than the the 90+ with standard handle bars.I learned sumpin new today.Imagine that.

 

[ben2go]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-8-23-12

I been dealing with health problems since my previous post.Today i got a chance to do a little work.I got the brake system swapped from my black 89 GS500E over to Project Lite Tourer.I am slowly rebuilding my black 89 GS systems while getting Project Lite Tourer back to running condition.Once I get it running and get my titling issue taken care of,I will tear it down for paint.My black bike is my daily rider, and I want it in good shape while I finish Project Lite Tourer.No pics of the work.My son had my camera batteries in his video game controller. :

 

[Big R]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-8-23-12

Glad to hear you're back at it Ben. You've got a pm coming........

 

[ben2go]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-8-23-12

Glad to hear you're back at it Ben. You've got a pm coming........

Thanks Rich.Taking it slow.PM replied to.

 

[ben2go]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-8-23-12

I will be busy this weekend but hopefully Monday I will be back on this project and making some progress toward first start up.I finally got my daily rider back up and running after some maintenance and mods.I am getting excited about this build since I am back to feeling better.

I am also trying to find a good set of used black bars to fit this bike.I'm hoping for a little more height and pull back.Not much.Just a little.The ones that are currently installed are slightly tweaked and I can see a wrinkled up weak spot in the bars.

 

[Big R]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-8-23-12

Ben, I have some black super bike bars if you want them. They have been drilled in a couple spots and have some minor rust spots though.

 

[ben2go]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-8-23-12

Ben, I have some black super bike bars if you want them. They have been drilled in a couple spots and have some minor rust spots though.

How do they compare to the stock GS bars?I can sand and paint them when I paint the bike.The ones pictured above are stock GS but are slightly tweaked.

 

[Big R]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-8-23-12

You're looking for "more" rise and pull? They probably aren't what you need then. Sorry, I misread the earlier post.

 

[ben2go]

Re: 92 Suzuki GS500E Project "Lite Tourer" Restore To Running Condition-8-23-12

You're looking for "more" rise and pull? They probably aren't what you need then. Sorry, I misread the earlier post.

Ok.Cool.I had seen them mentioned over on GST but I've never seen a set in person.I scored a bigger new style tank from adidasguy and I need a little more height.The pull back isn't as important.Oh,I also scored a fairly good condition old style tank from him too. Good guy to do business with.

 

[ben2go]

A quick update here.I been trying to get my daily rider on the road.That damn bike is killing me.Anyway,here's the update on Lite Tourer.

Last time I left off I had installed the rebuilt rear brake system from my daily rider.Here's the pic I am late delivering.

I started cleaning up the charge rotor side of the engine.I robbed the original rotor and starter clutch for my daily rider.Big mistake.I am going to fab a tool to reinstall the rotor.It's a press fit using nothing but the bolt to hold it on.Bad design as I have had rotors spin and ruin the crankshaft on these bikes.

I mentioned earlier in my post that I tried to move the bike with a seized chain.Well,the chain broke the clutch actuator(push) rod.This is going to be a pain.I got all new Suzuki parts and seals for the replacement.

I am pushing to get this bike going for spring break 2013.My girl and our kids are going to visit her mother.I am going on an adventure with this bike.I am planning to ride as much of the Blue Ridge Trail as possible.See here for info. http://advrider.com/forums/showthread.php?t=632804