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GS500E rebuild, 1989 style

WolfTechnics

Forum Apprentice
Hi guys,

I've been working on 2 GS500e's that I am building up to be the best looking GS500e's out there (in my opinion;)). I've been keeping track of the progress on a forum in my native tongue but I figured I'd start a thread here as well.

You might remember me from the GS400/500 GR650 hybrid build which I started here in 2014, 12 frikking years ago! I'm happy to say that finishing that project is still very much in the planning, although it will be a couple more years. I've always been very much in the habit of allowing things to enter into my life which distracts me from actually finishing anything. In the last couple of years I have started to shed some of this burdening weight off of my shoulders and shrinking the baggage I continuously drag behind me through life. I've adopted a household philosophy of minimalism and together with my beautiful wife we run a low maintenance, clean and peaceful household. Besides that I have stopped my powder-coating company which I ran besides a full-time job, I've downsized from a large workshop to a 1.5 car garage and did away with lots of things that distract. Also I have sold my Nissan 350z, a money pit, an energy pit, a black void sucking up all thinking power needed for other thing also (yes that thing was fun). Gotten rid of my beater car, which had an endless, ever growing "to do" list attached to it, and have gotten a daily car with a not so endless "to do" list attached to it.

And now, with a baby boy on the way (our first!), I've decided to keep my hobby's purely to motorbikes, I need to focus, and can't allow my energy to be diverted over many different things anymore, many of which end up dead ends anyway.

Now, everything I do, everything I plan, eventually it has to lead to actually finishing the most extreme small capacity GS ever build, the GS450 hybrid build. I need to finish it, it occupies such a large part of my brain, it has become one of my life goals. But before I can do that, there is something I need to get out of the way first.

...boxes...boxes full of parts, two motorbikes and parts for a third stacked up in boxes, bins, tubs, you name it. I've grown to understand that looking at unfinished projects, projects without plans or actual actions to do something about it is a massive energy drain, a leak if you will. So I decided to finish the GS500e's that are housed inside those boxes first.

Now at the end of this emotional dribble lets talk actual actions and plans.

For clarity sake, I own 3 GS500e's, one of which is fully custom, and I keep track of that one in the GS450 topic (updates soon!). One of the other two remaining GS's I have owned before, put a GSXR-750 front fork on it, rode it for a couple years and then sold it. I have bought that bike back some years ago and it has been collecting dust ever since, let's call this bike "Woodcutter" due to the large amount of sawdust it had collected over the years. The third and last GS500e I own is a random GS500 I bought from someone, the bike was pushed into some bushes and was heavily corroded all over. I've been calling this bike in Dutch "Struikrover" which loosely translates to bush-bandit or highwayman, let's keep it short and call this one "Bandit".

The plans are to rebuild both Bandit and Woodcutter to an OEM+ standard. Over the years I have learned to appreciate the stock look of the GS500's, as fun as they are I always believed them to be not very good looking, now I always enjoy seeing them. There will be only slight difference between the two bikes, these difference are, but not limited to; Clip-ons vs superbike bars, front forks. There will be no cutting, no welding, and no crazy custom paint colors or anything. I will paint these bikes in the one and only really good looking paint scheme, 1989 black with red and silver, white wheels. The only real big modification will be the GSXR USD front forks.

Summary of end-goals for both bikes:
  • 1989 Black with red and silver decals, white wheels.
  • Engine cases, cylinder and head all appropriately painted.
  • ALL hardware freshly yellow zinc coated (deviation from OEM).
  • GSXR750 front forks (1996 SRAD & 2001 K1)
  • OEM Belly pan
  • OEM Headlight fairing
  • GSF600F/Katana 1994 front wheels with double 320mm discs.

I already have two rare OEM belly pans, and 2 much rarer OEM Suzuki headlight fairings. I may or may not be permanently disabled after selling some crucial organs to be able to afford the OEM fairings, seriously, I could have bought a whole good-condition running GS500E for that money. Also I have already acquired two GSX600F/Katana wheels. I have chosen this type of wheel because it has dual disc brakes and the same styling as stock GS500e wheels. The wheel hubs will require spacers to lineup the discs with the calipers, but more about that later.

The color scheme is shown below, it is not my photo, I found it on a sellers listing, but it is the color scheme I am going for. But mine will have the more aggressive looking thicker USD front-forks, and the headlight fairing. I may or may not go for non-OEM blinkers and mirrors though, I think they are just too big to look good.

The decals are being made in Poland as I am typing this, I send them some OEM decals for the belly-pan as they had no archive on this, and the NOS OEM decals are all but useless for anything else as they let go of the backing paper.

1989_suzuki_gs500e_img_6758-4-82679-webp.2261416



To be continued...
 
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Now, as these bikes are stripped to their last bolt already, and stored in boxes, there are no interesting photos to be made of the state they are in, so I'll start with details. I've been disassembling the engines to prep them for paint, and to get a feel for the state of the engines (need to know how much money to reserve for parts).

Let's start with the Bandit engine:
img_20260723_184944_005-jpg.2261417


As you can see, it was a real bush dweller, dirt, spider-webs, dust, rust, you name it. I've certainly never cleaned the damn thing since I got it!
img_20260723_192853_244-jpg.2261419


The clutch was brand new to the specifications, a good start.
img_20260723_191346_429-jpg.2261423


All discs in good condition, and flat.
img_20260723_191351_469-jpg.2261425


A good opportunity to use my brand new clutch tool.
img_20260723_191453_900-jpg.2261427


I always remove the top end first before removing the JIS screws of the gear changing mechanism, they have lock-tite on them and are easily stripped. I want to put the engine case on its side to undo the JIS screw properly and/or use an impact driver if I have to, its just easier with the top-end removed.
img_20260723_193811_670-jpg.2261428


The camshaft chain-guides don't look terribly worn either, I will be re-using these!
img_20260723_192950_473-jpg.2261430


The head will be needing some love and attention though, Although let me tell you, this wont be a full overhaul! good enough is good enough.
img_20260723_193831_917-jpg.2261431


img_20260723_193817_576-jpg.2261432


Here you can see the carnage the bike's nomadic lifestyle has caused. Don;t you worry though, all will be cleaned and prepped for painting to make it look brand spanking new again.
img_20260723_194136_497-jpg.2261433


Some more archeology.
img_20260723_194140_670-jpg.2261434


Pistons are fine, some visible wear and tear, but I will be re-using them most likely.
img_20260723_194900_169-jpg.2261435


Some scratches in the cylinders though, some of them can be felt with your fingernail. I might have to get another one...maybe. I'll have to get new piston rings as well if I do...🤔
img_20260724_155636_535-jpg.2261436


Top cylinder block in the photo below is a spare one I had on the shelf, looks to be off of an F model because of the oil cooler holes. I might use it as the cylinder walls are in better condition, I'll have to come back to this later and decide.
img_20260724_155650_060-jpg.2261437


Cleaning the area around the shifter shaft, I don't want to pull this out while dirty as it will scratch the aluminum bushing on the inside.
img_20260723_195322_096-jpg.2261439


img_20260723_200350_252-jpg.2261438


You won't be the first to forget these two allen head bolts.
img_20260723_200735_433-jpg.2261440


Results!
img_20260723_201734_263-jpg.2261444


Gearbox seems to be in excellent condition.
img_20260723_201740_337-jpg.2261445


Adding another box to my collection.
img_20260724_152406_659-jpg.2261446


I don't think this engine block had much KM's to it, gauging by bearing condition and the condition of the chain guides. It's not my focus right now to replace all the bad parts, that will come later. The focus will be on getting the two frames painted asap so as to be able to build two rolling frames. That will reduce the amount of parts I have on the shelf massively and give me better oversight on what I have or have not.

To be continued...
 
And we continue.

I've started on the head, removing the valves.
img_20260726_171149_092-jpg.2261496


It's all quite nasty. this will require some cleaning later on.
img_20260726_171254_133-jpg.2261497


Removing valves one by one.
img_20260726_171456_753-jpg.2261499


img_20260726_171546_453-jpg.2261500


img_20260726_171735_089-jpg.2261501


Et voila:
img_20260726_172620_395-jpg.2261502


img_20260726_172617_400-jpg.2261505


A valve only its mother can love.
img_20260726_172626_408-jpg.2261503


This valve, even its mother...anyway, you'll get the drift:
img_20260726_172632_117-jpg.2261504


That's it for Bandit's engine for now, it will be stored in boxes for a while until the cases are painted.
img_20260727_170213_443-jpg.2261919


The frames are just here hanging on the wall, waiting for their turn. My GS450 frame up top, and Bandit's frame below it. Also visible are the OEM fairings I have acquired, stuffed inside the frames.
17850798809814986993370582418075-jpg.2261506


Woodcutter's frame on the floor, and one Katana wheel on top of it.
17850799146421262835520881136517-jpg.2261507


The USD forks, waiting for their turn.
17850800689288846874437307129297-jpg.2261511



To be continued...
 
Last edited:
Let's start on Woodcutter's engine:
img_20260727_172729_535-jpg.2261920


Nasty bussiness.
img_20260727_172744_885-jpg.2261921


Two broken exhaust bolts...great...
img_20260727_172813_485-jpg.2261924


Loads of sawdust all over.
img_20260727_172755_565-jpg.2261922


img_20260727_172804_325-jpg.2261923


img_20260727_180230_247-jpg.2261925


img_20260727_180232_232-jpg.2261926


There's a weird pink color on the valves.
img_20260727_180237_488-jpg.2261927


And, after an hour or 2, this is the result:
img_20260727_181258_444-jpg.2261928


To be continued.
 
As I said earlier, the Katana front wheels require spacers to make the narrow wheel work inside the wide USD front forks. It took some effort but I have acquired all necessary information to be able to draw up these spaces in FreeCAD.

ParameterKatana (GSX600F/750F)GSX-R750 K1GSX-R750 SRAD
Hub thickness (between discs)88,80128,00130,00
Nominale adapterdikte per zijde-19,6020,60
Disc Diameter280,00320,00320,00
Disc-PCD86,0091,0091,00
Disc mounting holes5,005,005,00
ID disc centering hole64,0069,1069,10
Bearing diameter42,0052,0052,00
Shaft Diameter16,0025,0025,00
Height of centering shoulder left5,80--
Height of centering shoulder right10,60--
Hub outside diameter109,00--
Threads disc mounting bolts.M10M10M10

Now I wanted to try and draw this up myself, and then have it manufactured in Hong-Kong at JLCNC.com.
schermafbeelding-2026-07-28-172557-png.2262189


They came in a week or two later, super fast!
img_20260812_132247_802-jpg.2266784


Some errors, but it was a learning experience, next time I'll do better!
img_20260812_132259_181-jpg.2266785


Very pleased with the quality:
img_20260812_132303_069-jpg.2266786


It's a perfect fit.
img_20260812_131804_455-jpg.2266787


img_20260812_131750_339-jpg.2266788


Brakes fit as well, very important!
img_20260812_131736_005-jpg.2266789


To be continued...
 
Back to Woodcutter's engine.

It's very clear this engine has a lot higher mileage to it, this chain guide will have to be replaced.
img_20260729_161825_521-jpg.2264118


Also this balancer bearing ain't fresh anymore.
img_20260729_163904_941-jpg.2264119


And just like bandit's engine, I will be removing the valves.
img_20260803_144517_338-jpg.2264120


Most definitely these were leaking a bit.
img_20260803_145814_167-jpg.2264121


img_20260803_145816_820-jpg.2264122


Now it's time to do something about these broken bolts on the exhaust side.
img_20260803_150632_387-jpg.2264123


img_20260803_151443_879-jpg.2264125


img_20260803_151448_722-jpg.2264126


using a lot of patience, heat, penetrating oil, a high quality left-handed screw extractor and a careful application of appropriate force, absolutely nothing happened. The screw extractor eventually stripped out the drilled hole. I switched tactics and went for helicoil inserts instead.
img_20260803_151740_789-jpg.2264127


Done.
img_20260803_155234_128-jpg.2264130



So far for the engine blocks, I haven't really decide on how I'm gonna do the painting yet, that will have to wait. First big thing is building up the front forks. i need them to make headlight mounting brackets, and brackets for the OEM headlight fairings. The brackets for the headlight fairings will set me back well over $200 dollars for a single one. I want to try and make them myself. Also I'll be needing the front forks to finish the wheels an all. No point in having it painted/powdercoated and not knowing it is gonna be a good fit or not.
s-l1600.jpg
 
Congrats!

You probably hold the record for the most pictures ever posted by one person, on one day, on this forum. (Of course, the day isn't over yet!) :eek:
 
Last edited:
Nice!

Those engine innards bring back memories...

Funny you mentioned the oil cooler models; a friend once bought a GS500 with a seized engine (2001, I think?). The PO had somehow run it low on oil, which these engines do NOT tolerate, and caused widespread destruction.

He paid a shop good money to install a used engine. Unfortunately, that engine also seized within a few miles, the shop wouldn't do a damn thing about it, and the disgusted owner sold the lot super cheap.

What we found was that the shop missed the fact that the replacement engine was a later model with an oil cooler and ended up blocking the passages to the oil cooler by using the old oil pan on the newer engine.

We found a good crank, bought new bearing shells, rings, gaskets, etc. from Suzuki and I built one good engine from the best of the piles of parts.

To work around the oil cooler issue, we used drain plugs to stop up the fittings in the oil pan leading to the oil cooler, then drilled a passage between these areas so that oil could still flow as if a cooler was in place. Worked great!
 
Thanks for the story! must be a bad shop if they don't claim responsibility after a breakdown on the way home from their shop.

I've actually never owned a newer GS500 with the oil cooler, and you got me perplexed here for a second. Somewhere over the years I have mixed up bits of knowledge, and mistakenly have been thinking the two 2nd air ports below the exhaust ports were for an oil cooler, they're not!

Do you remember if the stock oil cooler has an thermostat of any kind?
 
This is why why I've always been partial to, and absolutely prefer, the old roller bearing crankshafts.
 
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