Hey everyone,

Just want to recap on what happened with me recently.  The motor died due to no oil, and as it turns out, I spun a bearing.  Rear wheel skidded like hell, I pulled the clutch in time.  Here are some pictures:

Here's the crankshaft...  Some definite scarring from the bearing.


Here's the piston connecting rod.  If you can see, the bearing is f%&ked!


Here's the iron sleeves for the cylinders.  They've got scoring too and should be worked on...


Anyway that's what I'm dealing with!  Hopefully there's a talented machinist with an eccentric lathe nearby that can solve my problems...

I've been told that if I have machining done, that it should be in increments of .5mm (not the .005" SAE shaZam!, as zookie doesn't sell parts in this increment).  Anyone been in this situation before???

Sorry, that would be way over my head, I just always make sure that there is plenty of oil....

Maybe since you have it all tore apart, you can bore it and put larger pisons in it?

just get some emery cloth and polish it out, and put a new bearing in.

I agree with VFRocket. Get some 78mm pistons and bore those sleeves out and bam, you get a 541cc GS. You should do it, man. It'd be great and you know it.

I just so happen to have a useable crank, will have to check if its got rods on it or not, might be cheaper then having the crank "Polished" and attempt to track down the UNDERSIZED bearing to fit.


make a reasonable offer.

The cranks toast  :guns:
Just get the one from Blueknyt. I've got craploads of rods laying around if you need some.
Run a hone in the cylinders to see if the marks will cleanup.
If not, you can go up to 1mm bigger with stock pistons.

Blueknyt - what state is usable?  Does $150 CAD sound reasonable?  

Bob - I will see if getting the cylinder sleeves honed cleans it up.  The machinist at the place I went to to have a look at it suggested doing that.  That 1mm larger limit - did you get that spec from the service manual?

useable as in no worse cleanup then a junkyard crank, ive got a little surface rust on it that would basicly wipe off ,   ive got 2 cranks sitting on my bench in the shed and 2 more sitting in cases to be pulled yet, ill pony up the best of the 2 and clean it up . i wouldnt bat an eyelash  to run either one of them in my engines, fact i have a set of 500 cases i was gonna start assembling with one of those cranks.  If your not in a rush for it, ill see about get at them in the next 2 days (doctors still running me around for my knee) both still have Fly wheels and starter clutches mounted on them.  as to the price, let me check into the exchange rate before agreeing, ill also need your address so i can get accurate shipping cost.

Bob - I will see if getting the cylinder sleeves honed cleans it up. The machinist at the place I went to to have a look at it suggested doing that. That 1mm larger limit - did you get that spec from the service manual?

Suzuki has piston kits in .5 mm over and 1mm over.  

Quote from: Bob BroussardBob - I will see if getting the cylinder sleeves honed cleans it up. The machinist at the place I went to to have a look at it suggested doing that. That 1mm larger limit - did you get that spec from the service manual?

Suzuki has piston kits in .5 mm over and 1mm over.  

So you need a kit if you do it?  I want to know if I can hone it a bit, and use the same pistons and rings (cause they're still good).

If the cylnder is good you can use your pistons. But you might as well put some new rings on them.
The downside of the oversize pistons from Suzuki, is they don't sell rings alone for them. They do for the stock pistons.
the piston kit comes with piston, rings, wrist pin and circlips.
You should get new ciclips along with the rings.

Blueknyt - PMed you address.  Let me know.  A machinist has my crank right now and he's waiting for my call on what to do.  He still has not given me a price for the procedure - he's looking for someone who specializes at cranks.

Man I miss riding...

ok, ive taken off friday (tomorrow) to get some of this stuff done as it looks like i am going to have knee surgery in the very near future (next 10days or so) and wont be able to do with ease for few weeks.  if i read the exhange rate right, 150 CAN is 128.00 US,  100 for the crank + shipping was what i was thinking to begin with. so once i know total (fri) shipping might be closer to 50$ US.  ill try to get a pic posted for you too

OK, thanks a lot.  I'm going to get my crank back from the machinist and tell him I've found another for sale.

It sounds like you're going through quite a bit with your knee, so take it easy and I hope your surgery goes well.

Also, just off the phone with the machinist and he said the procedure involved removing the clutch and magnets, chroming over the marks, then shaving it down back to spec again, so I could still use original size bearings.  He quoted me for $225... Anyway if we can get this worked out Blueknyt it seems you'll be saving me quite a bit of money.

Quote from: Blueknytuseable as in no worse cleanup then a junkyard crank, ive got a little surface rust on it that would basicly wipe off ,   ive got 2 cranks sitting on my bench in the shed and 2 more sitting in cases to be pulled yet, ill pony up the best of the 2 and clean it up . i wouldnt bat an eyelash  to run either one of them in my engines, fact i have a set of 500 cases i was gonna start assembling with one of those cranks.  If your not in a rush for it, ill see about get at them in the next 2 days (doctors still running me around for my knee) both still have Fly wheels and starter clutches mounted on them.  as to the price, let me check into the exchange rate before agreeing, ill also need your address so i can get accurate shipping cost.

Blueknyt: How much for the cases???

hmm, dont know really, wasnt really thinking of selling them. spose i could, i have 2 GS450 engines for parts that are silver and those cases are the same. the spare 500 cases i have according to prev owner are already machined for larger sleeves to fit so im not really looking to part with those.  i could be willing to strip down one of the silver cases though, this would also free up another crank,Counterballece shaft, tranny gears for sale too.

Quotechroming over the marks, then shaving it down back to spec again

its good in theory and has probly been done many times with success, not sure i would trust it though, specialy on a rod pin. should somthing not be quite right with surface prep or what ever to allow that plating to chip or give up you would be in the same shape but now all the time and money from previous rebuild.

You're probably right.

Anyway let me know tomorrow if and when things get moving.