I'm just replacing the one valve, valve guide, valve spring seat, valve spring retainer, cotter valve, tappet, and valve stem.  At least that's what I'm planning on doing.  I'm looking for the cheapest way to get it back on the road.  If I had enough to replace all valves right now, I would.  can I get by with just doing what I have said?

I think you really should put new rings in the pistons.

Now, see that's what I'm talking about!  I need advice like that.  Tell me what I NEED to do so the engine will last, but lets not go overboard though.  Adding a turbo kit is out of the question here...

New rings it is.

For the cost of 1 of these from suzuki, you could buy most of the kit form kibblewhite. Get 4 of everything and then swap what you like. BTW kibblewhite seats and valves I am sure come in the 3 angle version. You'd save money doing that too. But I guess youd blow more than that installing all the seats instead. You also need to deck the head. Those things warp as you run it.
One important and very very counterintuitive aspect of 4 stroke motors is ... head is way more important for good running and long durable life and most of all power and driveability that cylinders and pistons pale in comparison. A hone and ring job will do, but you need to get the head right to ahve good power from it.
Cool.
Buddha.

Hi there,
Sorry to hear about your engine problems.
Yes, definitely, you want to replace the rings on both pistons whenever you pull the cylinders and remove the pistons from their bores.
Use one of the OLD rings to clean the ring lands (that's what the piston ring grooves in the pistons are called) and clean the pistons well with solvent before installing the new rings and reassembling the pistons into the bores. Be sure to use engine assembly lube on all parts so they are lubricated when the engine is first started again.
A good valve job is critical, per the specifications in the GS500 shop manual.
Also replace all gaskets as you reassemble. You want to do this work once, not take it apart and redo it later.
Best of luck, bub,
Trwhouse

Going to order parts on Friday finally, but need to be sure of the parts that I absolutely need.  Here's the list from bikebandit so far:

  Part Number     Description                         Unit Price
    480473-001  VALVE SPRING SEAT          $2.87
    480215-001  TAPPET                            $25.48
    480351-001  VALVE,EXHAUST                $38.31
    480460-001  COTTER VALVE                 $1.09
    480452-001  VALVE SPRING RETAINER   $3.80
    472452-001  VALVE STEM OIL               $4.40
    475720-001  GUIDE INTAKE VALVE        $10.46
    473168-001  VALVE GUIDE RING            $0.76
    477272-001  GASKET SET                     $127.19
    478333-001  RING SET,PISTON              $26.28
                                               
Subtotal: $240.64

What exactly is the name of the part that is chipped in the picture below?

Quote from: lewismug on July 29, 2008, 07:22:11 PM
Going to order parts on Friday finally, but need to be sure of the parts that I absolutely need.  Here's the list from bikebandit so far:

  Part Number     Description                         Unit Price
    480473-001  VALVE SPRING SEAT          $2.87
    480215-001  TAPPET                            $25.48
    480351-001  VALVE,EXHAUST                $38.31
    480460-001  COTTER VALVE                 $1.09
    480452-001  VALVE SPRING RETAINER   $3.80
    472452-001  VALVE STEM OIL               $4.40
    475720-001  GUIDE INTAKE VALVE        $10.46
    473168-001  VALVE GUIDE RING            $0.76
    477272-001  GASKET SET                     $127.19
    478333-001  RING SET,PISTON              $26.28
                                               
Subtotal: $240.64

What exactly is the name of the part that is chipped in the picture below?

The chipped part in the pic is the exhaust valve guide.

Oh yea, you can find it as a GS500 Kit form kibblewhile for under that $250 and the stuff will blow suzuki away. $38 for an exhaust valve, gimme a break.
Check with Bob Broussard how good kibblewhile stuff is.
BTW I will sell you a cherry head for $75, and do a 3 angle job on it for an added $25.
Cool.
Buddha.

Kibblewhite website lists a kit for a Suzuki® • GS500 E • 1989-2000.  My bike is an '02.  How much difference? 

What would be included with the head if I purchased it from you Buddha?  Would I need to buy all new valves, tappets, and all that, or would they come with it?

All in it. I would do the 3 angle job if you preferred. Its a brand new - very very low mile head. But it is black not silver. I dont have matched buckets, I would fit buckets by hand and check before sending it to you. None of them will bind up.
Kibblewhite stuff, should fit 02. Call them. Also ask them if the valves come 3 angle cut or what not.
Cool.
Buddha.

So, right now, is the head together or in pieces?  Would I need to buy valves, send them to you, and then you send everything to me once completed, or is your head ready to go right now?  If it is ready to go right now, is it all stock and  would it fit my '02 block?

Head is in 1 piece. Its got great everything. Very few miles on it. It only does not have buckets. It will fit an 02, just is going to mismatch.

We can split the valves, 3 angle cut them and refit it, and it will be like or better than new. Suzuki did such a lousy job on these. My head has also been decked already. I decided I will 3 angle cut em just before I need to use it.

Cool.
Buddha.

I will come out cheaper if I get the head from you without you doing the 3 angle job on the valves.  Then all I would need from bikebandit is a gasket kit.  How much would you charge me for the head if I sent you mine in exchange?

I think mine would've lasted forever if the tappet hadn't gotten stuck.  I don't rag the bike too much, and I mostly do interstate miles.  Lemme think it over and run it by the wife.  I'll let you know sometime tonight.

I dont need another head except to make some gruesome experiments.
What else other than broken valves and guides. You figure I will be able to grind off any imperfections and use it wihtout it destroying the CC volumes ?
I dont think its worth even shipping it, but OK how about I pay for shipping mine for you shipping it. I will need cam towers for it for sure, so if those are broken I'll pass on even that.
Cool.
Buddha.

I'd like to be next in line for that cylinder head if lewismug doesn't get it 

Lewismug - Hit me by say 9 am EST tommorow with $.
Ry_guy - if he fails to you got to 9pm tommorow. You want 3 angle job on them ? $25 if you do.
Fair enough ??
Cool.
Buddha.

Can't by then.  Would have to be Friday.

OK you have to noon friday - that enough ?
Then Ry_guy gets an extra 24, to saturday say sunday midnight.
Cool.
Buddha.

Ry_guy, lewismug backed out. Its yours now and like you said I have dropped it off at the engine shop. Contact me, for paypal info, I'll need that (obviously) ASAP.
Cool.
Buddha.