From Dust to Glory: Restoration of GS500

[7thgear]

Suzuki GS500
Model: 1992 Police Auction

Found it standing on the mechanic's workshop on one of my visits. It was about six months ago. The first look of the bike made t clear that there was no major damage to the bike, which is not very usual for auctioned bikes from the era. So the first look made its impression on me that this could be one perfect bike for the restoration.
Moreover, the bike had recently been in use with someone so obviously it had not been standing in the dark for too long, another plus.
Here is how it looked at first:

[7thgear]

My experience with the blue GS has been pretty good by the Grace of Allah. Whats good about GS is that its parts are relatively easily available. If the bike is perfectly restored, low maintenance costs coupled with better fuel economy means peace of mind. Here is a pic of my blue GS before I post others:

[7thgear]

The engine needed complete check up and overhaul. Complete new paint was obvious and the same for wiring. Front disk brake and calliper was from some 80s model bike and looked hideous so it also needed replacement.

[7thgear]

Expected time for the whole restoration was two to three months, however it was not till the end of five long months that I finally got the bike.
At first the bike's chassis arrived with new paint job done. All black.. I got medium length handle bar for the bike, coated with matt black. Front forks base also comes in matching black, while disk brake and calliper is painted golden. Sorry for the compromising quality of pics here, these are mobile pics taken inside the workshop.
Note the plain black fender on its first trip to the painter's shop.

[7thgear]

With the arrival of chassis from painter and newly painted rims and brakes etc. the parts were assembled to give it the bike's shape. tyres are mounted, disk brakes installed, oil pouring air bleeding in progress:

[7thgear]

Front fender returns from second visit to the painter's shop. Its looking cool now

[hidalgo]

as i have seen the finished product , it has literly made me drool , what an amazing resto man , thumbs up

[RocketScience]

Talal bhai !!! Ik chonta sanu ve de dena...

Pics in post # 5 & 6 are not appearing

[Juste]

Excellent Restore thumbs up for you bro! Do share more pics.

[7thgear]

Talal bhai !!! Ik chonta sanu ve de dena...

Pics in post # 5 & 6 are not appearing

Pics in #5 and 6 are visible to me. Maybe some error on your side.

[7thgear]

With the arrival of chassis from painter and fitting back of rims and tyres engine was opened for inspection. Some pics before engine was sent for new paint.

[7thgear]

[7thgear]

Inspection of engine internal parts revealed that it had locally made valves in it, which were replaced by new valves. The rings were also worn out and replaced with new rings. Engine head was damaged on the outer side so replaced. Carbs were in good condition and needing cleaning only, rest everything was good to go. Apart from that in electrical bike needed complete new wiring and CDI unit was also in bad shape so replaced with one in proper functioning condition. Pulser plate also needed replacement which was nowhere available at Lahore so was ordered from Karachi.

[7thgear]

Engine arrived after repaint while tank was still with the painter. Tank and pulser plate were the last parts to arrive. Most of the wiring had been completed and the bike assembled during this time. Engine back in place..

[7thgear]

The final product. received about two weeks ago.

[7thgear]

Check out the tank now, after painted thrice

[7thgear]

[7thgear]

Talal bhai !!! Ik chonta sanu ve de dena...

Sure bro

[talhabinomar]

Restoration project was good par process kay middle ki pix nai hain aur narration with detail nahi hai. I hope that the effort and the time plus money you have invested on it, pay off soon. Par ab detailed Photo session banta hai.

[Juste]

This is your 2nd GS500 or is it first one?