And now, for something completely different...

[Mr. J.J.]

Good evening, everyone; new guy here with a question. First, a synopsis; I bought a nice Suzuki GS450L some time back that is becoming very tired. I had always wondered if a GS1000 or GS1100's pistons and rods had the same pin location and rod length as the 450, so I might build a 500 or 550 out of my little Suzi. I had wondered this for years and recently was talking with a Suzuki dealer that is known for racing, and he told me "Oh, you don't have to do all that." and I asked why, and he said; "The GS500 Katana; the sport bike: built on the same crankcase; all the parts are interchangeable."

Okay...

I have accumulated all the parts I think I need to give Suzi a badly needed vitamin boost, and I only foresee 1 major problem: The frames are different, so the exhaust ports exit the heads at different angles. The 500 has 9 fins, while the 450 head has 7, and since this is a highway/road bike, I'm going with the better cooling. Has anyone had a similar problem, and is there an adapter somewhere that I can get to use the 500 head with a 450 frame and exhaust system? Also, I have acquired a GS500 oil cooler, which the 450Ls never had, so I would like to know how the oil lines run out of the 500 engines, if anyone has a picture they could post, I would appreciate it. (I got my parts off of Ebay, so I've never dismantled a GS500 engine...)

Oh, and I said I got this bike sometime back. I got it a long time sometime way back. I bought this bike new. I ordered it because the dealer didn't have a black one in stock. I got it with an adjustable backrest & luggage rack, highway bar, and cruise control. Thursday, March 12th, 1981. I'm putting a GS500 cylinder block (also has 9 fins instead of the 450's 7), 1mm over GS500 pistons, and the GS500 head (with the GS500's higher performance cams) on my original crankcase to preserve my original serial number. I still have my original tag, and in 3 years, I will be able to put it back on Suzi. It's not just everyone that can say they've been on the same bike for almost 35 years... 

Well, thanks in advance; have a great day, everyone! 

Jeffrey

[Big Rich]

There has been a couple 500 motors put into the 450 frame, and something has to be changed for the exhaust angles. Either a custom exhaust is made, or the frame has to be cut / welded / fabbed.

As far as the oil cooler goes from the Gs500F, you'll need to use the motor from a 2004+ (?) GS500. I can't speak for the exact differences to use the oil cooler, but I know the 450 motor won't just accept it.

[jacob92icu]

There was recently a big debate on whether or not the oil cooler even does anything anyways. This may save you a lot of trouble:

http://gstwins.com/gsboard/index.php?topic=63086.0

Take a look at that and see if you even want to go through with the hassle.

[BockinBboy]

I believe this oil cooler adapter setup sold by a forum member will fit either a GS450 or GS500 (that doesn't have one already, of course).

http://gstwins.com/gsboard/index.php?topic=62499.0

... So there are ways to get one on there, if you really want it.  Its a little expensive, but consider the price for other farkles on bikes and then I don't think its out there on price at all.

- Bboy