Hello everyone!
I need to disassemble the engine of my 2008 Suzuki GS500, but unfortunately, I don't have enough money to pay for labor, otherwise, I won't be able to afford any internal parts that may need to be replaced. My father is a diesel mechanic and works with trucks and fleet vehicles. He has King Tony torque wrenches (5-25 N.m and 20-100 N.m).
How complex is the GS500 engine? I'm thinking of doing it myself, following the service manual and using online videos for reference during disassembly and reassembly. My only concern is measuring the clearances of the parts. I was thinking of taking the parts to a machine shop for measurements, and if anything needs to be done, they can handle it.
Considering that I've never opened an engine before and only have theoretical knowledge, but access to the necessary tools, and planning to take my time, is this doable? I'm also motivated by the learning experience, DIY satisfaction, and the savings involved.
Thanks in advance!
Engine rebuilds have been done by inexperienced builders but I wouldnt recommend it. If you do, plan on the cost of a replacement engine in case it goes fun bags up.
Rebuilding an engine can be quite rewarding. The GS is a fairly easy engine to rebuild, with a lot of information about. a dial indicator and a good set of feeler gauges are a must. Now that Ive done my due diligence, good luck. We are always here to help if you get in a jam.
What exactly is wrong with the engine?, why do you need to rebuild it?, I rebuilt mine with minimal tool, if your dad can source some measuring tools for an evening or two you will be fine.
We can help you though it. It is super rewarding to do also. I can send you lots of pics of mine to get an idea of what to do .
I started on recently mainly just because I wanted to do it. I'm on the reassembly side of things and you can definitely do it, esp if pops has the tools and extra things you might need, which isn't much. The manual is pretty good to step by step and also there are some great yt videos and of course, here. I'd say go for it.
Hi everyone!
The idea of rebuilding the engine myself comes from a lack of money for labor costs, so I won't be able to replace the engine if it breaks.
I believe no one is born knowing how to do anything – it's all about practice. So, the plan was to follow the manual, watch videos, and take advice from all of you here in the forum. If I spend money on labor to have someone fix it, I won't have enough left for parts.
The issue with my bike is a bit of play in the crankshaft. I'm not sure if it's intentional or not, and I don't know if it's possible to fix it without opening the engine. I've attached a video so you can get an idea.
I was planning to open the engine and take the parts that need to be measured to a machine shop. I believe they have all the necessary measuring equipment there, as I don't have anything myself.
Just to give you an idea, the labor cost they're charging me here is equivalent to about 1/3 of the bike's total value. With the parts included, I think it could go up to 2/3.
Thanks!
Quote from: Bautitz on September 20, 2025, 04:11:41 AMHi everyone!
The idea of rebuilding the engine myself comes from a lack of money for labor costs, so I won't be able to replace the engine if it breaks.
I believe no one is born knowing how to do anything – it's all about practice. So, the plan was to follow the manual, watch videos, and take advice from all of you here in the forum. If I spend money on labor to have someone fix it, I won't have enough left for parts.
The issue with my bike is a bit of play in the crankshaft. I'm not sure if it's intentional or not, and I don't know if it's possible to fix it without opening the engine. I've attached a video so you can get an idea.
I was planning to open the engine and take the parts that need to be measured to a machine shop. I believe they have all the necessary measuring equipment there, as I don't have anything myself.
Just to give you an idea, the labor cost they're charging me here is equivalent to about 1/3 of the bike's total value. With the parts included, I think it could go up to 2/3.
Thanks!
It's hard to tell from your video, but is the play in the crankshaft side-to-side or up-and-down? I believe it's normal for there to be some transverse (side-to-side) play, but if the play is up-and-down, your bearings are shot.
Also, is your bikes operation and sound normal, or are there obvious clacking noises? If your bike sounds normal, there's probably nothing wrong with it.