Norwegian 1979 GS500E restoration.

[Guest]

Almost done now! Connect battery + and refill petrol into the tank and it should fire up. Or so i hope.

Today I did the following:

Emty the tank of old gasolin/petrol. New brakefluid and bleed the brakes, welded a new tip to the sidestand, put on the rotors on the wheel and put the wheel on, new taillight glas, attached the carbs properly , adjusted the rear shocks and many other small tings.

Loads of pics taken today, including pics of new retro helmet.

7A9A3F29-1953-4C85-BA2D-75460D00E66D by Kenneth H, on Flickr

BD874FA3-4582-4C65-9F08-FDAF395AE044 by Kenneth H, on Flickr

7F1C2DFD-5ABC-46F2-8CAB-2F649604A134 by Kenneth H, on Flickr

DF08909A-D78E-4F8E-87BB-DF202614F38E by Kenneth H, on Flickr

6489E8CA-FA52-4553-8AF0-FACB59633A21 by Kenneth H, on Flickr

DBF2FB4F-084B-441D-8EA5-11B6430083C8 by Kenneth H, on Flickr

968C3440-922F-4D92-872A-E502CA64620F by Kenneth H, on Flickr

9CE3E2B6-163A-43B9-BCED-BAB8ECF91E10 by Kenneth H, on Flickr

D1644F4C-A7F8-4B18-85D3-583A1117E4BF by Kenneth H, on Flickr

E761AACD-D654-4504-A83C-73BE1277103A by Kenneth H, on Flickr

573E299E-3712-40E0-9142-D4C793263A35 by Kenneth H, on Flickr

B1E354B6-7ECC-4CA3-8E3C-8838539FCADB by Kenneth H, on Flickr

2D922A8F-9199-4658-8E6B-93750F6D3AA3 by Kenneth H, on Flickr

 

[Guest]

PART 2:

573E299E-3712-40E0-9142-D4C793263A35 by Kenneth H, on Flickr

B1E354B6-7ECC-4CA3-8E3C-8838539FCADB by Kenneth H, on Flickr

2D922A8F-9199-4658-8E6B-93750F6D3AA3 by Kenneth H, on Flickr

5793C3C9-5156-45C9-BC1F-035EBE0600EC by Kenneth H, on Flickr

0E393A54-2464-4E65-A986-D8464BE690CC by Kenneth H, on Flickr

 

[LarsKroghStea]

Nice work!
Do you know the diameter and offset for your front discs? I have a gsx750 1981, and I've heard the ventilated disks are a good upgrade form the unventilated ones. Expecially when they are wet. I have plans for a fork swap on mine and won't be using them after that. I live in Norway too, so I could ship them to you cheaply. Won't be for a while, just wanted you to know

 

[Guest]

Nice work!
Do you know the diameter and offset for your front discs? I have a gsx750 1981, and I've heard the ventilated disks are a good upgrade form the unventilated ones. Expecially when they are wet. I have plans for a fork swap on mine and won't be using them after that. I live in Norway too, so I could ship them to you cheaply. Won't be for a while, just wanted you to know

Nice! Would need to buy your cslipers too then. I don?t know diameter or offsett but i can measure and give you the numbers i Come up with. Would be nice if that could be done, clever update.

 

[GSXR7ED]

Wow!

Lots of pics/updates.

Lookin’ good! Enjoy.

Ed

****

 

[hampshirehog]

Nice! Would need to buy your cslipers too then. I don’t know diameter or offsett but i can measure and give you the numbers i Come up with. Would be nice if that could be done, clever update.

The discs plug straight in - my 550 is wearing the set donated from a GSX750. Your 550 calipers will work fine but those off the 750 won't plug and play because of the offset due to the clearing axle on the 750.

 

[Grimly]

GSX750 seems to be one of those using the L-style forks with the axle up a bit. If it's using the later calipers (and it should be) those will fit a '79 bike with the right mounting brackets from something of the 80 or 81 years with the std forks.
This is exactly what I did with my '79 - it had those horrible hockey-puck calipers and I fitted a set of 80-onwards calipers from a GS1000 of some unremembered model, but I had to source them where I found them, and one of them came attached to an L bracket. Not a great setback, as the caliper easily mounted on to the non-L bracket and fitted the forks.
The same calipers were fitted to virtually all of the GS range at the time, and were backwards-compatible on some (probably the majority with some outliers) bikes, at least.

I just love Suzuki parts-bin engineering

 

[Guest]

The discs plug straight in - my 550 is wearing the set donated from a GSX750. Your 550 calipers will work fine but those off the 750 won't plug and play because of the offset due to the clearing axle on the 750.

How thick are the 750 vented discs?

 

[hampshirehog]

How thick are the 750 vented discs?

They are the same dimensions as on your 550. The only difference is the vent holes.

 

[LarsKroghStea]

How thick are the 750 vented discs?

I measured mine wich is 4,74mm. The manual says they should be 5.0 +/- 0.2mm from the factory. There's not much of an edge to mine. I also have the '79 GS1000 calipers as I was told I needed those when I swapped to spoke wheels. Is was told so because the gs1000 calipers taper on the inside (which supposedly was needed to clear the spokes) and the original gs750 ones didn't. I using the original calipers, so either someone has swapped them earlier or the info wasn't right. If you need them, you could have those for free. They need to be serviced, and I haven't tried them myself, but the ebay buyer I bought them from said they were OK. Where in Norway do you live?

2020-05-22_09-12-34 by Lars Krogh-Stea, on Flickr

 

[Guest]

Norwegian Gs500e 1979 , it runs!! Video in latest comment

Norwegian Gs500e 1979 , it runs!! Video in latest comment

Yay, it started!!! All electrical worked and it started right away. Only one minor hickup, i put in a new gasket and oilfilter. The gasket was a bit tricky to get in place, thought i had, but it got a little leak. Dunno if i should try to use like a liquid gassket in addition to the one that is there(brand new) or try one new with or without mentioned liquid gasket sealer. Advice is appreciated. Here is a little startup video, second start i believe, Sorry about soundquality but it is a cell phone so.... and inside a hall so the sound might be a bit warped. click on the picture to get forwarded to the flickr video.

IMG_0455 by Kenneth H, on Flickr

 

[Gorminrider]

Looking great!
just a thought, but i see you repainted the starter motor cover...I found it's useful to coat it with a somewhat gas-proof clear coat because the odd drip from draining the carbs etc attacks a laquer, (if that's what you used) and then it went rusty again....urethane spar varnish seems to work for me but you can likely find similar...

 

[Guest]

So I just discovered Salty Monk?s brake kit and just paid for a complete bracket kit and a pair of Ninja calipers. Now i gotta get me F3 or Fireblade rotors.

 

[Guest]

So I just discovered Salty Monk’s brake kit and just paid for a complete bracket kit and a pair of Ninja calipers. Now i gotta get me F3 or Fireblade rotors.

How would you get rid of the liquid gasket afterwards? Is it easy to clean off? My oil filter cover is leaky.

 

[Guest]

How would you get rid of the liquid gasket afterwards? Is it easy to clean off? My oil filter cover is leaky.

It is fairly easy to get tid of later on. Max 5minutes work i would say. Sometimes you just rip off the whole thing in once. If there is some left then you could scratch it of with a small flat screwdriver. I USE Permatex blue. Think i bought it at the Jula store.

 

[Guest]

Bought this electric ignition conversion kit to get rid of points. Not fitted yet.
B14B7574-F9E0-4145-8397-DFAA1DDE5A8A by Kenneth H, on Flickr

2A35CF2E-54DD-465D-8590-D1DEB589BB9F by Kenneth H, on Flickr

Had the bike for import approval, all good except for the smallest oil leak on the right fork.... so I bought two new seals and dust covers for the forks and new thicker oil. Worked really well and was a bit easier to fix than I feared.
95494AEB-7AAD-4084-B38F-07C270BDD4E7 by Kenneth H, on Flickr

Also I found out that the stator did not charge while driving. So I bought a new one(on the picture it is the old stator) and a new rectifier. Apparently previous owner fitted an rectifier from another bike, Kawasaki, and some dodgy wiring too that got fixed. Measured voltage as per workshop manual
specified: 5000 rpm and 14,25volt. Anything between 14 to 15 on 5000rpm is good.
963DBB12-B4B2-485C-8D74-DA6A13A24B5B by Kenneth H, on Flickr

Then finally i found the small hobby paint brushes and paint the letters on the badges that goes on the sidecovers. Needs a top clear coat. The 3D printed badges will never be perfect but better than just having one tired original one.
7344CE50-D1F1-4A25-B065-0EE095E8D329 by Kenneth H, on Flickr

 

[Guest]

Did some further polishwork on the left side as I was not happy with previous work I did on it. Better now.

629A6025-6455-4C4F-86FF-FC8B547BC369 by Kenneth H, on Flickr

0FE54324-2E4E-4EB1-9851-A30326C47EFA by Kenneth H, on Flickr


14E11E78-2B2B-4FDB-8049-1147AEEF6AB4 by Kenneth H, on Flickr

 

[Big T]

Looking better!
Are you riding it, or just polishing it?

 

[Guest]

So smooth, I need to get polishing too.

 

[Guest]

Looking better!
Are you riding it, or just polishing it?

As of now just polishing.... lol. This bike is an import. That means i gotta show the bike to the dmv(i think you call it? Or was that in Britain??) I did that a few weeks back and they checked the bike and papers i got. All good except the smallest oil leak On right fork. Changed seals on both forks and oil. Sadly due too Covid 19 things go veeeery slow at dmv. Also gotta order appointment with them online and waiting list that is ludicris. New appointment with them tomorrow. Then it will pass. Next thing is to pay up some tax and order a license plate and order a new appointment to pick the license plate up. If i am lucky i can be driving the bike in little over a week.