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General GS500 Discussion / Re: -- GS500 picture game --
« Last post by mr72 on November 16, 2019, 11:16:16 PM »
Remnant of my gravel pile behind the bike. Probably half a yard there.

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Tard Farm / Re: Last Post Wins - V3
« Last post by yamahonkawazuki on November 16, 2019, 08:19:49 PM »
The rest of the bikes are envious lol
Aaron
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Tard Farm / Re: Last Post Wins - V3
« Last post by peteGS on November 16, 2019, 07:57:02 PM »
Hahaha that's entertainment right there!  :thumb:

Awesome ride yesterday, between the fresh rear rubber and getting the VM33's finally sorted I had the best ride on my favourite roads yet, and we had six Kats all up and no other brands or models either, just 100% Kat  :thumb:

Untitled by starpoint73, on Flickr
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General GS500 Discussion / Re: New bike, terrible rattle/shake at 3500+ RPM
« Last post by mr72 on November 16, 2019, 01:30:04 PM »
Sorry to hear that. I hate to say it but I bet you find a bent rod and broken piston skirt. The original root cause was probably not fixed. But I hope I'm wrong.
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General GS500 Discussion / Re: -- GS500 picture game --
« Last post by mr72 on November 16, 2019, 01:28:32 PM »
Welp, yesterday I moved about 90% of my giant pile of gravel. Might still post the pic with the GS out front of what's left. Maybe it'll be enough.
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Tard Farm / Re: Last Post Wins - V3
« Last post by yamahonkawazuki on November 15, 2019, 08:54:49 PM »
Been binge listening to Kevin bloody Wilson. Lol
Aaron
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Tard Farm / Re: Last Post Wins - V3
« Last post by peteGS on November 15, 2019, 07:13:04 PM »
Hahahahahaha glad those Tesla engineers are doing the important stuff  :icon_lol: :D :bowdown: :thumb:

Rego renewed on the Kat and new rear tyre on... I had forgotten how much difference fresh rubber makes, feels so much better now! Did about 35km to start scrubbing it in ahead of this morning's ride  :thumb:

Ordered a set of clubman 'bars for the 450 as well, a whole $29 including free postage, and my mate should have that set of ZX12 rearsets for me today.
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General GS500 Discussion / Re: New bike, terrible rattle/shake at 3500+ RPM
« Last post by Kylll on November 15, 2019, 07:12:17 PM »
Just FYI, I have no direct experience rebuilding an engine-- just being logical trying to read the original post and boil this down:

1. you discovered a broken piston skirt, decided to replace both pistons, both rods and the rod bearings
2. while disassembled, the crankshaft had resistance to 30 degrees of motion *while no rods or pistons are installed*. But you assembled and tried to run it anyway.
3. pulled it apart again, you found metal bits in there, attempted to sand it smooth and reassembled
4. engine now has a loud knock and mechanical shake

Is that about right?

Because if so, I'd say the crank is probably bent, main bearing is scored or spun, which would tear up the bore in the block, etc. One end of the crankshaft is very scorched. If it were me, I would have never reused that part, and I bet there is additional damage to the bore where the crank seats in the block.

While it was apart to the degree you have had it, it would have made sense to pull the crank and have it machined like you ordinarily would for a typical bottom end rebuild and you would have caught any problems there. I'm guessing this is in your immediate future anyway. But I bet there is more damage there than you anticipate right now. With that kind of heat, who knows what else is smoked in there.

Frankly if you are looking for the quickest, most economical way out of this, I think far and away the best bet is to find a replacement engine you can get cheap with a worn top end but good bottom end, then transfer the jugs and pistons/rings from your rebuilt top end to a free-spinning bottom end. If your original crank was bent or if the rod journal damaged on that side then you are probably in it for at least one new rod and of course rod bearings for the replacement engine. However given your current conundrum and the amount of time you've put into this, I think I'd carefully inspect any replacement bottom end and probably go for a wholesale rebuild including new main bearings and machining the crank. In for a dime, in for a dollar.

Good luck, and at least you are learning a lot in this process! I admire your willingness to dig in and fix this yourself.

Thanks for this.
There was only resistance in the rotation with the original conrods on. Once they were replaced with new bearings rods and pistons it was perfectly smooth.

There was a bit of shrapnel between the con-rod and where the counterweights are on the crankshaft. A bit of sandpaper and all was well.

Gonna strip the engine AGAIN today to see what caused the seize/how much damage is done.

I live in New Zealand and there are virtually no spare parts here. Shipping fees from the UK (where parts are cheap) are absurd. Paid $100 for both pistons (with conrods) but had to pay $70 shipping 😂


Thanks everyone.
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For Sale / For Trade / Wanted / Hot Deals / Re: WTB GS500 tank
« Last post by cbrfxr67 on November 15, 2019, 06:35:26 PM »
is there a wera thing going on here?

i didn't even know what a ysr was,... looked it up,...looks fun
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General GS500 Discussion / Re: New bike, terrible rattle/shake at 3500+ RPM
« Last post by Kylll on November 15, 2019, 06:34:22 PM »
Don't know what fixed it, took the whole engine apart and reassembled the entire thing and couldn't find any obvious errors.

Idled perfectly, nothing wrong. Let it sit for 2 minutes to burn off some oil i had on the exhaust headers and then gave it a rev to 7K.

Slowly moved from 1.5k to 7k (8ish seconds) and the motor made a loud CLUNK, heard some metal shards fall to the bottom of the motor and it's seized now.

Great :)
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