Engine types? What are the differences?

[TarzanBoy]

I am about a week away from possibly attempting an engine swap on a 2005 GS500.   All indications thus far say that I will probably be swapping in a '92 or '90 motor into the '05 bike.

What differences are there between the different engine revisions?  How many revisions are there?

thanks in advance!

[sveach]

As far as I can remember, cable driven tach vs electric driven, and the oil cooler will be absent on the older motors. If you're not going naked, probably gonna want to retrofit the cooler onto the new motor.

Old carbs are 1 mm smaller, and different jets. Old carbs have 2 jets, new carbs have a mid main added, for 3 jets total.

Someone else will chime in with what im missing.

[Jay_wolf]

New Carbs Have 2 Throttle cables , instead of the 2000-  one cable ,

[TarzanBoy]

Why do the new carbs need two throttle wires?

My first bike was an '89 GS500 with spot-welded brackets for 2004 fairings.  There was no oil cooler and I never had temperature issues with the bike.
S*****h <- shhhhh witness protection ... himself did most of the fabrication.

Here's a photo

As far as I can remember, cable driven tach vs electric driven, and the oil cooler will be absent on the older motors. If you're not going naked, probably gonna want to retrofit the cooler onto the new motor.

Old carbs are 1 mm smaller, and different jets. Old carbs have 2 jets, new carbs have a mid main added, for 3 jets total.

Someone else will chime in with what im missing.

[The Buddha]

I think the 89-95 motors were a lot better built than 96-00, which was better than 01+ and 04 and later it all went to sheiete (dont now come after me with torches and pitchforks) ... but I have had more trouble with the ones that own 96+ bikes in my local crowd.
The motor itself is almost the same. Put the ignition plate and the advancer from the new one on and the tach can run off the wiring harness. Plug off the tach drive on top if you do.
Oil cooler - bweeeeh ... wont be needed, just dont sit in traffic in summer much. If you have air even at 10-15 mph it will work. Especially if you jet it right. If you do need it, when the motor is outside dril land tap in the right spot for it. No clue where that is, but should be drillable. That's how suzuki did it.
Old or new carbs same thing, they all work. I am working on running 04 carbs on my 95. So run the 04's carbs.
Motor itself is the same, some of the bolt on's were different.
BTW I didn't weld any of the brackets except the 2 on the bottom by your foot. All the brackets were fitted with thread bosses just like stock, or just with clamp on brackets (tail especially had all clamp on brackets in 16 ga stainless steel no less. They freaking shredded my hands. You can reverse it to 89 specs in 10 mins flat. You only ned a grinder for the 2 on the bottom. That frame was so nice looking, pity that Jacob decided to get 04 mod done on it, I'd have done it on a shitty frame and then got it powdercoated.
Cool.
Buddha.

[dgyver]

Why do the new carbs need two throttle wires?

They are for push & pull. A safety feature. If one fails the other will still be able to close the throttle, instead of relying on a spring to close the buttleflies.
No problem if you already have the 2-cable carbs.

You can still use an electric 04+ tach on an older motor. There is nothing that needs to change.

Swap the signal generators.

An oil cooler swap is more involved than just drilling and tapping. There is additional plumbing on the inside of the motor along with an restrictor to deal with the pressure required to pump the oil through the cooler. Kind of a bad design since it uses the same single oil pump to supply the oil cooler... by reducing pressure to the rest of the motor.

[The Buddha]

Very good D, didn't know that, the GSXR's have a 2 stage pump ... and doesn't the GS oil cooler return to the pan. Like nice cool oil isn't getting to the important spots.
Now maybe that oil cooler is what is killing the motors You think.
Cool.
Buddha.

[dgyver]

Very possible, on the early deaths of the 04+ engines.

IIRC, the oil cooler dumps into the oil pan.

[The Buddha]

The GSXR oil cooler IIRC sends out to the lubrication circuit (high flow). Bearings are on the high pressure circuit. but it does have the effect of cooling the parts and of effectively cooling the oil down. In fact that GSXR air/oil Genre is very very good at shedding heat, go near it and it will be like its a BBQ pit, but internals are much better than a comparable kawi or honda or yamaha. They just pour heat and make a racket.
Cool.
Buddha.

[TarzanBoy]

My R6 does run warm.  Every Yamaha I have ridden ('96 FZR, '99 R6, '03 R6) likes to wash the rider in engine heat.   Typical city riding engine temp in the (admittedly hot Georgia) summer is usually ~200ºF

[The Buddha]

They all do that, the air oil suzuki's were notorious for being really really really hot. This is old school, pre 90 GSXR. Somehting like you ride up and park it, 5 mins later you tock the handle bar and it could be too hot to touch. They had some weird very shallow fins and thin walls that let them shed heat like nothing else. I dont have a reference point to compare it to really.
Cool.
Buddha.

[DoD#i]

Both 92 and 90 use the plain sprocket (89-93) as opposed to the sprocket with a boss (94-up)