Rebuild Log

FearedGS500 · October 23, 2006, 09:56:53 AM

if your going to mess with the front you might as well do the back .. you might look in to what its going to take to maybe do a 750 swap

front and rear see if you can fit that in your budget .. check the local wreaking yards and ebay and see what you can find .. look on here to see what it might take to mod it to make it all work .. most of it sounds simple enough ...

RiderX · October 26, 2006, 06:12:34 PM

Alright here are the updates - engine is out. I have the engine stripped down further than what is in the pics, and it doesn't look too good. I think I may need stock pistons and have the old cylinders inserts pressed out and new stock ones preseed in. That is of course - if thats possible - any ideas?

Or the alternative - any one know of a bore kit for a GS 500e?

Anyway - here's the pics, ugly as they are:

Me needa lotsa da help!!

Happytrack44 · October 26, 2006, 06:36:44 PM

Find a running engine kit, with the carbs, the ecm, the wiring harness, All the stuff. and make a running motorcycle BEFORE you spend silly money on an engine build. Any mods on an un tested engine could be expensive and time consuming and unsucessful. Piecing the missing stuff is expensive. Find a kit.
Got one on ebay for the Horsey Project (91 GS500) For 175, picked it up in state next door. That was a great deal, and sometimes there are others! Good luck Rob

RiderX · October 27, 2006, 06:04:54 AM

Oh believe me - I'm looking into all avenues. I'll start searching eBay for a kit. I may have a line on a lot of top end stuff, so we will see how that goes...

Turd Ferguson · October 27, 2006, 10:47:37 AM

Awesome! You're making good progress! Keep us updated, I love project logs!

-Turd.

3imo · October 27, 2006, 11:10:50 AM

no doubt! keep us updated.

I am especially interested on your engine rebuild. I did a full rebuild/chop/restore on one of my GS's.

Here you can see my thread on that project. http://gstwins.com/gsboard/index.php?topic=24409.0

**this shows (sorta) the process I went through to remove the paint and rust for the frame. as well as my conversion from 95' fairings to 01' fairings.

it is my daily driver now.

Keep it up and post more pics.

ducati_nolan · October 27, 2006, 11:28:13 AM

Dose the engine even turn over ir is it siezed? I doubt that you'll need to put new sleeves in the thing, a bore and the next size up pistons should be fine. You could even try running a hone through it to see if it cleans up without removing too much material, you may get lucky. That being said, you'd hate to spend your time and money on a top end and then find out that your bottom end is trashed, and with the ammount of rust and corrosion in your top end I wouldn't be suprised if the bottom end was corroded too.

A used engine would be cheaper than a full rebuild, but if you can get away with just a top end that would be cheaper. It's a gamble.
Have fun

RVertigo · October 27, 2006, 11:39:40 AM

That poor GS...

I'm SO GLAD you're fixing it up.... Good luck with it! I can't wait to see how it turns out.

RiderX · October 27, 2006, 11:58:50 AM

The engine turns over just fine. I'm just worried about investing money in the top end just to have the bottom end totally hosed. I've got several leads on used engines now. So I will keep you guys updated.

3imo - I love your finished product! Any pointers on stipping the frame/wheels?

Jared · October 27, 2006, 12:35:21 PM

I have a bare 89 frame ( no title - I got it for parts- sorry the engine is long gone..).

I'm getting ready to get rid of it (it's minus the removeable section..).... If you want it for replacing your subframe...it's here in Pasadena, MD. Just come get it...
It's in my way....

And if you decide to say the hell with the whole project -- I have a 92 and a 94 sitting here waiting for me to finish them up and put them out for sale...

The 92 has the famous....or infamous camshaft end play noise...

But Anyway.... if you need a subframe...

dgyver · October 27, 2006, 01:00:13 PM

fyi...Suzuki does not make the +1mm pistons (75mm) anymore. I think they still make the +0.5mm pistons (74.5mm). Other options do exist for larger pistons like 78mm, but the total cost for parts/labor is around $350.

I do agree with D-N that the bottom end may (and probably does) have some corrosion as well. Pull the oil pan and see what resides there.

ducati_nolan · October 27, 2006, 01:38:19 PM

Since it turns over fine, I bet you could just hone it and replace the rings, reusing your pistons. Even if you take off a bit of material from the cylinders (porbally won't be much) you could get the next size up rings and file them down to the correct end gap. It should work just fine and it would be cheap, the only parts you need are the rings.

If you do decide to get the larger rings and file down the end gap, I'd recomend using the stock bore size oil ring.

Ne reason spending any more than you need to

RiderX · October 28, 2006, 06:01:51 AM

Quote from: dgyver on October 27, 2006, 01:00:13 PM.... but the total cost for parts/labor is around $350....

Hell - I've got an offer on a slightly used engine for less than that! I'm exploring engine and frame options right now. Should be coming to some sort of deal(s) by the end of next week. I'll keep you all posted.

I'm going to put the engine to the side for now - and focus on getting everything else off of my frame.

bettingpython · October 28, 2006, 05:22:44 PM

Some where on here there is a thread about building a larger displacemt engine you can use 79mm pistons from a 4 cylinder liter bike of some sort, cant remember where it's at but dig around if your going to bore the cylinderrs and have it apart anyway go big.

FearedGS500 · October 28, 2006, 10:24:12 PM

orrr you can go head get that new motor and get that poor gs back on the road... then save up some money and get that other motor moded out the end and just have one hell of a motor ready for one your other one gose out

RiderX · October 30, 2006, 07:28:00 PM

Just some minor updates...

Nasty Pistons...

I hope someone remembers how all this goes back in...

Old nasty carbs...

Pretty new(er) carbs! Much thanks to Jughead for these:

I'm waiting for some more info from srinath(sp?) on a new(er) engine, and I think that should work out nicely...

Egaeus · October 30, 2006, 07:33:47 PM

That's boiled in vinegar? Amazing! Berryman's going out of business.....

Jughead · October 30, 2006, 08:53:46 PM

Dang mine were Cleaner weren't They. Glad they Made it.That was super Fast for USPS.

Actually I didn't touch those Carbs at all.The Whole Bike is that Clean.

yamahonkawazuki · October 31, 2006, 01:34:58 AM

Quote from: Jared on October 27, 2006, 12:35:21 PM
I have a bare 89 frame ( no title - I got it for parts- sorry the engine is long gone..).

I'm getting ready to get rid of it (it's minus the removeable section..).... If you want it for replacing your subframe...it's here in Pasadena, MD. Just come get it...
It's in my way....

And if you decide to say the hell with the whole project -- I have a 92 and a 94 sitting here waiting for me to finish them up and put them out for sale...

The 92 has the famous....or infamous camshaft end play noise...

But Anyway.... if you need a subframe...

hey jared ne idea what youre goin to ask for one or the other?

RiderX · November 02, 2006, 09:27:06 AM

Mkay. I think I'm nearly out of things to tear apart. Man - I REALLY hope this thing goes back together with as few headaches as it cam apart... I know... pipe dreams...

Alright, heres the last of the dissasembly (i think):

I should be picking up a new(to me) frame this weekend. With title!! Woot! And the engine I'm waiting on pics of, so that will be next. Then it's off to strip & powder coat! Hooray!

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