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Thread: Project GS500 - Japanese becoming Spanish (Blue Bug)

  1. #1
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    Hello Guys, i am sharing my new project, i bought a GS500e (police auction bike) 3 months ago from Lahore, i want to rebuild it completely.so that i can use it for tour, in short i want a trouble free bike,...etc..
    AIM= Cosmetically upgrade old shape of bike to Spanish version,replace all old parts with new parts and complete overhaul the engine.
    i know its quite hectic and time taking job,so i have completed two major steps.
    1st i bought the bike :-)
    2nd bought all the parts from UK and thanks GOD they have reached Pakistan and i got them today.( i bought them 2 months back and it took almost 1 month to reach Pakistan from UK via air cargo.. CUSTOM cleared :-) )
    3rd step is in process i.e restoration .. All the restoration work will be done by BASHEER ustad, because i don't want any compromise.[/QUOTE]


    So finally ALLAH k fazal say project gs500 is complete.
    Job done.
    Alot learned.
    Time for project: 1 year 5 months.
    All cables replaced.
    New clutch plates.
    New spockets n chain.
    New head.
    New cylender.
    New ring , pistons.
    New timing chain.
    new tyres.
    new wiring loom.
    swing arm replaced donor 2003 gs.
    Engine chrome.
    Tank , tail and seat from my 2002 donor gs (my next project)
    New paint job.
    New meter dials.

  2. #241
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    Quote Originally Posted by MONOO View Post
    Original tank of this bike was in pathetic condition. Rust n welding etc.so instead of repairing it i used the tank of my 2001 gs which wass in way better condition.
    It had a fiber glass tail. But thanks GOD 2001 GS has a orignal plastic tail.so i used 2001 gs tail , tank n front head light on this bike.
    Cosmetic upgradez are reserved for my next project.
    I m sourcing all the engine parts again for my next project becoz i have used all the new imported parts on this bike.
    whats the purpose of two same bikes ?

  3. #242
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    basically i won a bid in auction so i got 2nd bike.

  4. #243
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    ok goodluck for that too..

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    Quote Originally Posted by haroon_1 View Post
    ISnt it possible to install an oil cooler, we can do it easily in any car. But i think it will be tough here.
    there is a dedicated website gstwins.com which have some details on doing it and how to do it..
    https://www.pakwheels.com/forums/motorcycle-travel-diaries/277725-sober-riders-visit-khunjerab-adventurous-way-via-nori-pass

  6. #245
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    bhaijaan aap ka project tou kafi late ho gaya hai

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    Quote Originally Posted by sul View Post
    bhaijaan aap ka project tou kafi late ho gaya hai
    Yup bro.late to ho gya hai.but good thing is k almost finish hai.

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    ALLAH karay aisa hi ho lakin main 5,6 din pahlay bashir ustaad ki workshop pay gaya tha aur aap ki bike 30percent bhi complete nahi thi why is that ?

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    Quote Originally Posted by sul View Post
    ALLAH karay aisa hi ho lakin main 5,6 din pahlay bashir ustaad ki workshop pay gaya tha aur aap ki bike 30percent bhi complete nahi thi why is that ?
    Engine overhauled and mounted on the bike. Carbs fit kernay thay.plastics and all paint parts are ready.belly pan paint hona reh gya hai. Wiring ho gye they. Exhaust 3 to 4 days tak milay ga.

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    Quote Originally Posted by sul View Post
    ALLAH karay aisa hi ho lakin main 5,6 din pahlay bashir ustaad ki workshop pay gaya tha aur aap ki bike 30percent bhi complete nahi thi why is that ?
    Basically when u r rebuilding bike from scratch us ma boht si chezain replace kerni hoti hain.it depends on us k either use new part or desi jugar ker lain. Meray project ma time itna lag rah ha becoz desi jugar nai kia abhi tak. New Parts ki sourcing is a big problem and time consuming job.

  11. #250
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    ok best of luck

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    Update.

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    Paint job after cutting cream and polish.

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    Tank ...
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    Tail...
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    Center piece
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    Mudguard
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    And finally belly pan
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    Quote Originally Posted by MONOO View Post
    Center piece
    @MONOO bhai as always just perfect work. but i think this font is a bit off! if you're going for perfection then i think you need to reconsider this center piece i hope you understand

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    Quote Originally Posted by ammarzahid View Post
    @MONOO bhai as always just perfect work. but i think this font is a bit off! if you're going for perfection then i think you need to reconsider this center piece i hope you understand
    I was trying to find original sticker for center piece but in the end i have to settle on this one.

  21. #260
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    Good going
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

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