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Suzuki GS 500 hard tailing

  • Thread starter Thread starter Guest
  • Start date Start date
G

Guest

Guest
Began to work on the project hard tailing my 500 GS. Chassis is actually the 1981 GS 550, and the engine is 500 GS from the seventies (I do not know exactly which year) for the German market reduced to 27 HP, in really excellent condition. For starters I have a few pictures dismantling the carburetor, which was a lot of rust because rusty tank, engine and engine position in the chassis. So for now, pics would follow that the project would go ahead.
 
carbs1.jpg

carbs2.jpg


carbs3.jpg

enginev.jpg

chassis.jpg
 
looks good so far. i had been thinking about hardtailing the 850 that i wadded up but have been too busy with my 750. good luck with everything.
 
kruns,

Your motor is the first 500 four cylinder I've seen. I've only read of them. I don't know much of how to complete a hard tail build but I'll enjoy watching your progress. Welcome!

Charlie G.
 
Kruns,


Do you have any plans to try to boost the horse power upward?

cg
 
Thanks piester and Charlie, I'll enjoy this project!
Difference between stronger and weaker versions of the GS 500/550 is in carburetors, air intake and camshaft and was created because of German law (probably because young drivers). Today there are also similar laws in some EU countries where power motorcycle must not exceed 100 HP. I do not plan to raise engine force, regarding the durability of the already high quality GS series engines, this is simply indestructible :)

http://www.bikez.com/motorcycles/suzuki_gs_500_e_1980.php

http://www.bikez.com/motorcycles/suzuki_gs_500_e_1979.php
 
how do you plan to hardtail it? cut it apart and weld it? i had thought about making adjustable rods. kinda like tierods.
 
I will present the progress of the last occurrence. chassis that I predicted for the modification was quite distorted in a car accident so I decided to put other proper that I also had. In the picture below You can see how we start place tank to the chassis and engine in the chassis.
That's all for now folks.

tank2g.jpg

tank1r.jpg

chassis3.jpg

chassis2e.jpg
 
No disrespect intended, but are you actually going to build this bike around the sportster gas tank? Thats, well different....
 
Kruns,

Interesting tank and frame combination. Have you altered the frame in any way? I am looking froward to seeing your bike being completed. It looks unique so far.

Charlie G.
 
2Henryinva: I wanted a small tank to distinguish engine as amuch as possible and the Sportster tank was a logical choice. I would say that it is not original but is a combination of proven and I like it.

2Charlie G: Frame was taken from one gs streetfighter with changed subframe, but now a complete rear end will be cutted of and goes to hardtail.
 
Wow, you had to have cut the bottom of the sporty tank a lot to accomodate the triple backbone. How many gallons does it hold with the modifications?
Is the petcock going to cause you grief with the engine or did you move the petcock location in the tank?
 
I plan to modify the frame (triple backbone) instead of reservoir, or at least planning to do so. Original tank holds 2.4 gallons.
I have not yet dealt with the petcock location in the tank, but slowly I will come and do this part.
Yesterday job: mounting rear swingarm (to find an ideal position of rear wheel) and front fork.

img3086b.jpg


img3085sj.jpg


img3087vk.jpg
 
Looking good, got a nice setup for getting the shape how you want and see the clearance as you go :p
 
new pics, I`m happy happy as a child, the motorcycle is finally on wheels!
p.s.: pozdrav zdravku, tomici i mariu! :-\\\


img3092x.jpg

img3093.jpg
 
Looks good! Glad I'm not the only one sticking a front fender on the rear! Wish I had another one for the bike I'm building now.

Nice job and Im looking forward to more pics!
 
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