A GS650 Build

mindtrip

New Member
Glad to finally join this board and post all my project phases here.

Last summer I received a free 1982 GS650G "Z" Model. The bike had been sitting out in the rain for many months, I believe since '95. Apparently the person who owned the bike before me decided to just put it away and never ride it again. A friend of mine happened upon the bike as he was his next door neighbor. He tinkered with the bike for a couple of months but never got it running. So he mentioned to me that he was getting rid of it and if I had a truck it was mine. I immediately jumped on this occasion and picked it up. Even had the title! Shoved that big ass biatch in the truck and got her home.

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As soon as I had some time, I started working on it. I have had experience working on cars, but not motorcycles. I thought...what could go wrong? In actuallity I found this bike to be extremely easy to work on. All the bolts (with the exception of the carb pan heads) cracked and spun off with ease. The carbs were a bit gunky, no seizures on this set. Bike turned over with new plugs, gas, oil, sock air filter (yes sock) carb dip, and a battery. Very cheap to get running. Cleaned her up a bit and took her for the summer.

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Later on in the summer, I dumped it and wrecked the headlight and gauge cluster. I bought a couple of things from DCC and said "I'll just fix this and ride it." I took it for a ride once, and said "Let's tear this thing down and build the bike that I want." I have never built a bike before...

From this
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To this
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First thing we figured...make the gas tank look a little more sporty

We hammered in the gas tank, bondo, sand etc. Then we sandblasted the frame and clipped off all the stupid stock tabs and electronics location. Were going naked and see-thru frame. All electronics mounted up under the cowl and gas tank. Lopped the rear tail off.

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Just screwin around here haha...first idea of a seat. Its starting to look like a cafe racer.
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CUSTOM paint booth. No heat in the garage so we had a space heater and a cardboard box

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I picked up some 500 degree high temp engine enamel from an auto parts store and sprayed the engine black. Planning on sanding off the fins to give that metallic contrast everyone wants!

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You can see the rear plate flaked. It was a little cold, I think I'm going to polish that back to shine and call it a day.

Started a couple of welds. Under the book there's a plate for the electronics. I also welded a battery support for under the cowl. It will be shaped and rubberized with grounding points.

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I'm not the greatest welder either. But I think they'll hold.
Started mocking up the electronics as well.

I'll be getting in the garage today, more pics will ensue.
 
Good start. Welds will get better as you go! 8) I Try overlapping the metal on corners like that since I'm "newer" to welding myself, instead of butting them up to each other. Keep it up!
 
thats not a seat mount. it is a battery tie down place. Shouldn't touch the cowl at all after were done. I am thinking i might have to introduce a hoop to support the rear of the cowl.

I was trying to get the battery above the suspension travel. So i took the oem rear fender and bolted it up to measure clearance. It just fits under. And with an AGM gel battery that will be no problem since the dimensions are so small.
 
Swivel said:
Cut the seat mount horror off and start again.The rest of Y'r work is very good for first attempt.That seat stop base thing will vibrate like a C*%#!.


Not that I know what i'm doing ...... But yea maybe use some thicker metal stock for the battery box
 
Battery should be charged. Getting the wiring completed today. Mocking brake lines and calipers.

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Mock it all up, and take some pics so we can see what you are thinking. I agree with possibly using thicker metal. What Guage is the stuff you've got on there now?
 
Alright...

A little update from the 650 build.

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http://vid1232.photobucket.com/albums/ff362/brton311/VID_20120429_185620.mp4

A little wire management and a custom battery box a fturnsriend is tacking together, new bars and a seat and it'll be rolling.

I decided to put the battery transversely across the frame behind the pods seems to be a better place than shifting that weight to the back.

Let me know what you think.

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seat glassed...first attempt ever

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the black flakes are some paint that was on the inside of the mixing container.

My buddy found a sportster tail light and plate frame at a swap meet... fits perfectly.

Adding some more layers tomorrow.
More pics to come.
 
Hey man. I've got the same bike and making mine a cafe as well. Just curious what you jetted your mains to when adding the pods? I see you still have stock exhaust... let me know, cheers.
 
If you mount the battery that close to the carbs i'd mount a fire extinguisher too...and be ready if a carb float sticks and you start dribbling out and that battery bolt gets loose enough to arc..... you'll basically be on fire
 
Re: Re: A GS650 Build

thekeezler said:
Hey man. I've got the same bike and making mine a cafe as well. Just curious what you jetted your mains to when adding the pods? I see you still have stock exhaust... let me know, cheers.

I haven't jetted the carbs yet but I'm gonna start with 115s

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Here's a pic as of late. I'm at work right now but I'll be posting a boat load of pics.

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