Hybrid motors (no not petrol/electric)

[Cerberus73]

At the moment I am gathering parts to rebuild my 1998 GS500 engine.. Am picky about aesthetics as well as mechanical reliability. My crankcases have the typical cracked front mount. And since I wanted to refinish the motor externally I decided to just completely go through it and fit/replace parts as required.

Well I got hold of a set of 2006 gs500 f model crankcases. But not the sump (oil pan cover) for that crankcases as I thought I could use the 98 engine's one. But can I? Or do I have to source the later type with oil cooler take off threads and also oil lines and a cooler? Also, is there a better and cheaper cooler I could use if it required fitting a cooler? Am in the UK so these parts are harder to find than in the US.

If anyone had these part if I need them they are willing to sell at a fair price I would be interested! But the postage can be expensive!

[BockinBboy]

Unfortunately, you cannot use the older oil pan on the '06... it also isn't as simple as getting an 04'+ oil pan and deleting the oil cooler by plugging the lines.  The '06  (and 04+ F models) has pressurized oil passage in/under the pan, and there is also a 'restrictor' of sorts (not sure of the correct term) that pressurizes the oil which goes into the filter, which is not on an E model without the cooler from my understanding.  If you were to simply fit the 98 pan to the '06, or plug the '06 - you would end up with too low of pressure and your oil pressure light would remain on - and for good reason too.  We have seen folks simply use the older E oil pan gasket on an F model by mistake and problems arise quickly with just that mistake, and the oil light will remain on indicating dangerously low pressure. 

I suggest fitting a take-off cooler and pan from and 04+ to remove worry about low lubrication.  You would just have to mount the lines and cooler rack on the frame (pretty straight forward), and do nothing concerning the inside of the engine.  There isn't much info out there on removing oil coolers, a little more about adding them - and even that deals with routing everything external on an E model. 

I just want to stress that these motors are particularly susceptible to catastrophic bearing/crank failures with low lubrication issues - its their flaw - otherwise, they are tanks for as long as they are lubricated well - check and change oil regularly.  I wouldn't want to increase risks related to the lubrication system of this particular engine.

- Bboy

[Cerberus73]

Well i have bought the correct oil pan for those crankcases with the oil take off. But i have not bought an oil cooler yet. as looking at the GS500F item, it looks pretty small, so I'm gonna see about fitting a larger cooler. Something with more than 3 rows anyways. i was thinking a 10 row job. and making lines up to mate the oil pan and cooler up.

Getting the standard Suzuki oil cooler here costs a small fortune (am in Scotland). as most seem to be located in the states, and by the time postage, import duties and the cost of the item are factored in. it ends up costing as much, or more than a new aftermarket item. Does anyone have information on what oil coolers can be fitted to the GS that won't stress the oil pump, but provide a good rate of cooling. i do plan on using this bike for prolonged touring.

[yamahonkawazuki]

Could be shipped as a gift to avoid the high duties?

[Cerberus73]

I asked but they wouldn't do it.. so it was back to square one... i do need to find a oil cooler and lines.. but to be honest for the price asked for a second hand GS500F one from the States (the ones located here in the UK i have seen are in shaZam! condition).. i can get a new aftermarket one which is larger (10 row or so instead of 3) and make lines up myself using braided hose and fittings.. i just need to work out the sizes id need, and what the GS500 oil pump could cope with.. hence why i asked on another post if there were any other Suzuki model oil pumps that offered higher volume and pressure but was a direct bolt in replacement for the GS500 one. i could then machine the oil ways a little to let more oil through to the head etc.