At 4am, here's the verdict. I bought a GS [1996] for 800$ not knowing that it didn't run right. Well, after a few weeks of running it, not hard but running it, I decided that it didn't run like a 500 should. I pulled it apart tonight b/c I was sick of the oil leaks. Low and behold, I found that the intake cam race bridge, or whatever it's called. Is broken. Both sides are broken in to two pieces in the same place on both f$%^in cylinders. I'm going to Suzuki tomorrow to order the new stuff to put it back together and I'm powder coating the rusty exhaust tomorrow. I enjoy this bike, I really do, but I urge everyone who buys one to please be weary of the man who just wants it gone.

If anyone knows where I am in this bike? Should I replace the cams or valves when I have this thing apart? I'm having a head job (<--hehe) done this weak too b/c I don't see any reason not to since the head is already off. If so, is there anything else I should do? It's got a V&H pipe and some jets I don't know about b/c I didn't do the jetting.

I forgot, is there anyone that can recommend a quality budget bore kit? I got to go to like 542 if possible. I'm also interested in custom lobed cams. Is this a pipe dream?

Quote from: fat_sac................ I'm powder coating the rusty exhaust tomorrow.................

I'd be interested in hearing how this holds up.  My experience is that even high temp. powder coating won't hold up at the head end of the exhaust.  Mine bubbled, smoked and stunk to high heaven.  I'm going to try VHT flat black flame proof coating (comes in a spray can and is supposedly good to 1500 deg. F.) next time.

Check out the thread "Want a 547cc motor w/ 78mm pistons?" at http://www.gstwins.com/forum/viewtopic.php?t=14401

For the exhaust, the conventional wisdom is that flat black barbecue grill paint from the hardware store usually works as well as, and sometimes better than high-temp auto-store treatments.  Mine lasted about 2 years, and now it needs to be brushed and sprayed again.

Quote from: fat_sacI forgot, is there anyone that can recommend a quality budget bore kit? I got to go to like 542 if possible. I'm also interested in custom lobed cams. Is this a pipe dream?

The thread of mine that Rema posted has all the info for a 541 conversion. There is not a kit available. I miss labeled the title as 547 instead of 541.

Megacycle cams (//www.megacyclecams.com) can do standard modifications to your supplied stock cams for $266 (see page 50 intheir catalog) or they can do custom grinds. You will need to contact them for the cost. There are another cam company but I do not recall their name.

I think some folks in the Brainerd area use Bill Bune in Anoka, MN: http://www.billbune.com  

I've bought jets there.  Lucky me, he's local .

Wow, thanks for all th responses. I'm definately going to get bbq paint now instead of powder coat. I didn't realize the powder coat is only cured at  a lil over 300 degrees sometimes.

I'm going to check out the 541 conversion right now. How well does it stand abuse? Like hi revs and racing? I'm hard on motors.

I built a 555 motor (79mm pistons) for track days and it is still running hard. I was running up to 12,500rpm without problems, and kept wanting to pull. You need heavier valve spring to do this. The only issue it that the bored sleeve is as thin as it can used. You do risk them chipping if running too lean. I have a chipped cylinder that came with one of the 79's. I have since sold the bike and it is being raced in CRA #30 at Brainerd now (and winning!).

The 541 I have was raced prior to me getting it. Not sure how many hours are on it, I could find out from the p/o. It spit a shim and put a hole in the head. This is the motor I am going to be putting in the track bike I am building.

New valve springs huh? Did you do anything to the valves when you had em out? What motor did the valve spring come out of?

What jet setup do you run with the bigger pistons? I have a V&H exhaust with K&N filter.

Necked the valves.

Springs are from Megacycle, page 50 in their catalog.

Here is the 555 I had....
http://gstwins.com/forum/viewtopic.php?t=18400

That's basically all the stuff I want to do. Looks like I'm going to be calling megacycle today. I need to call around to find a good machine shoop too. What about carbs? Any upgrades there?

carbs....flat slides or round slides, 34mm or larger They are pricey. Usually $300+