hehehe did I get myself into to big of a project?

[drkslayer]

On the left is the 90 with a title, on the right is a 92 without.

on the left a spun balencer... on the right a motor that turns over and has compression.

anyone have any recommendations for parts or maintenance on the 26k motor before I swap it over? As far as I know, it was a pit bike been sitting for a couple years.

I'm wishing hard this goes seemless.

[werase643]

get it running in the 92 before you swap it!!!!!!!
pull the carbs.....clean them!
pull the plugs....check for spark....clean or new plugs
check the valve clearances

if it runs and shift thru the gears....swap it

[drkslayer]

I got it running, and it has a nasty pop...


not that I'm a mechanic by anymeans, but it either sounds like the valves hitting the top of the piston, or the bearings in the piston, or the rod... something... it doesn't sound good... it definatly sounds like to repair, you need to crack the case... i don't think I wanna have 2 engines I can't figure out how to go back together in my garage... lol

anyone know any good mechanics in the western new york area?

[ben2go]

Pistons can't hit the valves in a GS engine.A bearing,maybe.Have you checked the valve shim to cam clearance?That can cause some knock and rattle.Could be a bad piston pin.More diagnosis is needed.

[drkslayer]

Pistons can't hit the valves in a GS engine.A bearing,maybe.Have you checked the valve shim to cam clearance?That can cause some knock and rattle.Could be a bad piston pin.More diagnosis is needed.

let's say that its the piston pin, or rod bearings... and I'm a noob thats gonna attempt to replace bad parts and bearings.

what would you suggest I get for parts, once I figured out what color code the bearings are?

so far the main bearings, rod bearings, piston pin, cam bearings, balancer bearings... what am I leaving out?

is there anything else that goes bad inside these engines? I don't want this to take all summer either. I'd like to do whatever i can to make this engine as close to new as possible.

is there a "rebuilding a gs500" for dummies? I have a manual I got off ebay, but it doesn't tell me what I should replace, or even where I could get said parts ya knw...

this noob needs guidance...

[ben2go]

Pistons can't hit the valves in a GS engine.A bearing,maybe.Have you checked the valve shim to cam clearance?That can cause some knock and rattle.Could be a bad piston pin.More diagnosis is needed.

let's say that its the piston pin, or rod bearings... and I'm a noob thats gonna attempt to replace bad parts and bearings.

what would you suggest I get for parts, once I figured out what color code the bearings are?

so far the main bearings, rod bearings, piston pin, cam bearings, balancer bearings... what am I leaving out?

is there anything else that goes bad inside these engines? I don't want this to take all summer either. I'd like to do whatever i can to make this engine as close to new as possible.

is there a "rebuilding a gs500" for dummies? I have a manual I got off ebay, but it doesn't tell me what I should replace, or even where I could get said parts ya knw...

this noob needs guidance...

The engine will need to be torn down,everything will need to be checked with a micrometer,bad parts will need to be sent to a machine shop to be remachined over/under sized.Bearing color codes? ?? Forget about that.You'll have to match bearings to the sizes that the machine shop machines your parts to.You'll have to have some specialized tools to tear down the engine.You're looking at 2 to 4 weeks depending on the machine shop.You'll need to use a machine shop that's familar with motorcycle engines, or be prepared to give them alot of case,crankshaft,balance shaft,piston,cylinder and rod demensions and tolerances.