Ok so i did everything i need to do to the donor motor and its ready to go in tomorrow morning..   So while waiting i figured i would tear into the blown one and find out what happened...  and well heres the pics

heres one of the sleaves 





here is the piston head semi lodged in the jug... we got it out with a quick push of the ratchet



heres down inside the lower part of the engine..



the lower part is a little scarred but i believe it can be honed or polished out. 




Here is the rod     






the best we can figure  The bolt to the rod fell off..(lucky me)  And from there everything pretty much went to shaZam!...

I will be tearing into the bottom tomorrow to clean out the rest of it and try to find some remnents of the bearings.   which are nowhere to be seen...  I would like to rebuild  this engine  if anyone can chime in with procedure and prices i would appreciate it..

As far as i can assume i will need

pushrod and pistons
jugs
crank
seal
bearings 
Besides  ebay and bike bandit   please point me in the direction i need to go...

thanks
Nasty

(thanks for sharing these pictures of the brutal aftermath)

yea i was worried that the oil had run out and that it was my own damn fault.. but  when i tore into today  oil leaked all over the table .then finding what we did in side the engine helped to prove that it was a freak accident.. so no i at least have peace of mind

That is a first for me.

Got a service manual? It will have all the info for the rebuild. Make sure you clean everything thoroughly.

I will have to look to confirm this but I should have pistons, rods, cylinders, crank. The bearings needed will be determined by the combination of the rods & crank and crank & cases.

are you certain (so far) that the crank journal will still be good ?

were you beating on her at the moment of death ? (not being an ass, just wondering)

how many miles did she have, regular oil changes, beating on her, etc ?

please please please keep that bent rod, or post it to me as a reminder shaZam! can go wrong REALLY fast out on the road.

I'm nominating that rod as the title picture for the wrenching section of the forum, if we ever have one

good luck with the build, keep us posted !

Dude, get a motor from someone. Cheaper and much less pain for you.
Cool.
Buddha.

The cylinders could be resleaved but get dgyver's parts I know their good.Might wanna get a crankshaft just in case.Check all the engine case journals thourghly and the crank shaft.How does the head look?Did and fragments make it thru into the head?Could have went thru the oil passages to get there or back up in the exhaust and intake ports.Clean the engine case oil passages reallly good.Use a long rifle cleaning brush to get in them, If you have one.

Sorry to hear about your bad luck, but thanks for sharing the pics!

im going to try to answer all of these....

Yes dgyver  i have a manual..  (bought after i bought the bike)  Let me know how much for the parts and i can see where my bank account sits...as far as the bearings  go  how do i know which size to use with what..   I might be able to get the crank honed or turned  doesnt seem that bad..

Ohgood... she was running straight and true at about 530 am in the morning a couple of weeks ago.. I was on my way home from work at orlando airport and i was cruising at about a constant 90 mph.  the rpms were not stressed.  The oil i changed regularly and she is a 96 with 26,000 miles..  Havent really beat on her the last two years ive had her.. and i just had the clutch replaced. valves shimmed. .and new seals added in december..    As far as the rod and piston head....welll those and other small chunks are sitting on my workbench im still amazed at them myself...

To Buddha  I already picked up a donor bike.. Drove across florida last weekend and picked up a 92 for  $450  (complete bike with forks bent the wrong way) but the kid had a complete set to give me also.  I dropped bothe engines out this week and cleaned, changed the oil, spark plugs, and a few other things on the donor engine today... will be swapping in tomorrow.

To ben2go   the head looks good.  just the one jug is split.. the piston head wasnt even punctured and no meatal fragments were up top.  After i get my bike up and running with this donor engine. I will strip  this one down the rest of the way and clean it all the way out with kerosene.  

IF i can get this motor back into working condition i will throw it into the 92 frame and re build the forks and fix whats wrong with that bike.  I already have a friend who will put a a mechanics lean on the vin of the bike so i can get a title for it seeing as it didnt come with one(  but the vin did check out clean at the police station before i bought it)  This way my fiancee might be able to have her own gs 500 to ride..

I checked ebay today for some parts  they seem to be running dry..  I guess thats the sign summer is here.  

Quote from: nastynate6695 on May 31, 2008, 10:39:21 PM
im going to try to answer all of these....

Yes dgyver  i have a manual..  (bought after i bought the bike)  Let me know how much for the parts and i can see where my bank account sits...as far as the bearings  go  how do i know which size to use with what..   I might be able to get the crank honed or turned  doesnt seem that bad..
...

Determining the bearings sizes is actually very easy. The crank and cases are stamped with letters. The combination of the 2 will determined the bearing size required. Look in the manual at the chart and it should make sense. Ordering them online sometimes does not have the color code (size) listed in the parts fiche. One of the sites does, maybe Ronayers.com since I just ordered a full set from them. Also, the bearings are sold per each and you will need 2 per.

I am heading out to my shop in a few and will see what I have.

sweet thanks man...let me know and i can see what my finances are...

I did the motor swap today and everything is working great.  i think i have to mess with my carbs float heights again but ill run it awhile to make sure... 

did learn something new.. the 92 front sprocket does not fit a 96.. and vice versa..  the 96 is too fat  or the 92's shaft is not long enough. either way you cant get the retainer clip back on..

The front sprocket changed in 94.

oh and see i thought the engines went unchanged till the f models came out..

Just dug out some parts. Amazing what I found that I forgot about... a GS450 motor that I was going to rebuild with GS500 top end. The crank I have is for that motor.

Anyway... cylinder, 1 piston with rings & wrist pin, 1 rod. $20 + shipping.

yea that works for me just give me till the end of the week so i know my finances are secure...engagement ring, plus mortgage and bills takes a lot out of me..  any luck with a crank 

Just PM me when you want it.

man that is harsh damage

I have the engine from my 97 sitting in my garage. Got the bike from my dad (gsJack) with 80,000 miles on it. I put 8,000 more on it before replacing it with a low mileage engine I bought off eBay. It was running strong right up till I pulled it, but oil consumption was getting excessive. The head is pretty much toast. One exhaust valve is has less than minimum clearance, with the smallest shim in it. I took the cover for the signal generator to replace the crash damaged one from my new engine. I would assume it needs oversize rings, or maybe bore out for new pistons. I know it's a lot of miles, but it's all there. It would probably be a couple hundred bucks to ship. I can put it on a pallet and drop it off at a shipper. There's a Forward Air located close to work that I've dropped an engine off at before. $50 and it's yours. You pay and arrange shipping.

uh thanks jp im good for now.. the only thing i need to get is a crank and bearings for the rod. not sure where you live at either...

OH yea  hey dg  should i worry about the crank balancer...seeing how its right in front of where the rod bent at... or are those things bullet proof..

I am in SC.

Doubtful that anything happened to the CB shaft, just a mass of steel. It is driven by a gear that is seperated by the case. The only thing that could be hurt on it would be the bearing surfaces. The engine stopped before any debris could get to them.