Dead 'new' engine? Advice on moving forward please?

[mullethunter3]

Hey guys, here's my story. I'll try and keep it concise.

My bike, 1992 GS500, had 42,000 miles on it when the engine spun a bearing due to lack of oil.
I found a donor bike on craigslist. It is a 2004 GS500F with 3,700 miles on it. I took the engine out of it and put it in my '92. I used the '92 ignition rotor, solenoids and carbs. All is good, right?

Problems:
- When the engine was hooked up, it made a small clunk and then a click. Then just clicks after that.
- After investigation, it was found that the engine WILL NOT rotate freely with a socket on the crankshaft. The spark plugs are out and the top end of the engine (the valve cover) was off as well.
- After much frustration, the engine finally turned over manually. However, there was a 'rough' spot where the engine seemed to be catching on something.
- Continued to turn the engine over manually until the 'rough' spot seemed to go away.
- Assembled the valve cover, but not the spark plugs to see if the engine would turn over by itself electronically.
- Turned over more than it did before but ended up with the same noises as before... clunks and then a click.
- Currently, just clicks.

I should note that when I bought the 2004 bike, it was sitting outside with no muffler or anything covering the exhaust. I realize it is very possible that the inside of the engine has rust on it, preventing it from moving. However, I am posting this just in case there is another way for me to get this engine running without rebuilding the entire top end of the bike. I have a donor motor for parts (my '92 motor is fine except for the crank). Or could this be a valve problem? Everything looks normal from the top, but I can't see the business side of the valves until I tear it down.

Anyone's thoughts?

[The Buddha]

Rust and stuck ... if it will turn over can run fine wihtout smoking and behave properly.
I have a 82 XS650 which had no spark plugs in it for years and was left in the weather ... stuck motor and a crank case filled with all sorts of garbage.
I managed to get it to run and it does not do anything untoward.

Sitting in the open with no exhaust can rust up something ... and yea it can get a valve snagged ... but it should turn past it quite easily. Look in there and see what that looks like as its beign turned by hand.

The other thing is, you may have a mis matched cam tower set.

It really reall really really pays to know what you're buying is good. I was at one time selling a motor from a running bike. Ride it and buy it type, and average took me up on that offer. That is the only way to buy em IMHO.

Cool.
Buddha.

[mullethunter3]

I would have been picky about it sitting out, but the parts bike was only $100.

So Buddha, are you saying that I can spray some stuff in there and keep turning it and it'll work itself out?

[The Buddha]

Yea spray pb blaster and hand turn ... though it should ahve gotten nice and good by now with a few turns ...

OK I read the post more slowly ...

OK open the left side and look for goats ... Yea after you find it has goats, please stare at it, then you can be part of the "Women who stare @ goats movie" ... remember, no goats, no glory.

Then dont be certain its just the top end. Top end will let it spin free, smoke, lack of power, oil useage hard starting, oil fouling of plugs etc etc etc ... Not turning over could be worse ... though I am thinking its something simple we're overlooking ...

Cool.
Buddha.

[mullethunter3]

Thanks Buddha.

I've already looked for Goat's. My generator magnet on the '04 engine is in much better shape than my '92 engine. I forgot to mention that I've been inside the left side of the engine and found nothing wrong.
I went earlier today and got some PB Blaster per suggestion IRL. I'll work with that a bit and see what happens.

[tt_four]

Did you consider just taking the crank out of the new motor and putting it in your 92?

[The Buddha]

Did you consider just taking the crank out of the new motor and putting it in your 92?

That isn't easy dude ... That is almost the same or sometimes worse than a bottom end rebuild.
Its a full on split and worse yet, the case where the bearing spun could have chunks of it missing on the old one.
If it broke the rod, as is common with rod bearings it could easily have hammered out the cases, and even if you have intact most everythign else, you have to mic everythign and get bearings in the right size.
Here is the next kicker. Bearings in different sizes are not available. You're gonna have to weld up and turn everything down to original size ... yea try 1000 to 1500 bucks.
Cool.
Buddha.