I bodged a pitbike doing this once. I know different engines but the principle is the same.

It was a tight fit and yet still, eventually the flywheel slipped, and mushed the pin (not really a bank breaker) but it knocked the ignition timing out so it wouldnt run. Your problems could be more fatal though. I'd buy a proper one that fits. I wouldn't trust a wobbly flywheel.

Flywheel is snug and fits fine. The ignition advancer (right side of the engine) that engages the pickups to tell the spark plugs when to go is what is wobbly.
This thing:
http://www.ebay.com/itm/96-gs500e-gs500-gs-500-e-timing-rotor-suzuki-/250728030802?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item3a608e2252

just fix that little dent up if it is not allowing the roter to sit down properly.Only thing you need to be sure of is it dosn't hit the pickup, otherwise you will be fine( TORQUE BOLT 17nm to 23nm)

Quote from: Dizzledan on February 24, 2012, 08:27:44 PM
I mounted it up, and found a new problem. My ignition rotor is bent or not sitting right. The bike fires up and runs fine (the ignition rotor doesn't hit the pickups), but it's noticeably wobbly when running. Does this pose a major problem that could strand me someday? I took it off and checked the pin (still there) but the back of the rotor has a little dent next to the cutout where the pin is supposed to sit.

The pickup's should be close to the rotor's nose, and not touch them.
Wobbly could be an illusion though. If not, it should be OK the nose is supposed to fly by the pickup's that's all that matters.
Cool.
Buddha.

Took my first spin of the season up to get gas, everything worked wonderfully. Went to start it to head on home, the starter kept spinning but wouldn't catch to turn the engine over. 1 hour later with my tools spread out in an abandoned parkinglot next door, I find out that the flywheel rotor bolt has worked it's way out. It seems that because the 1980 GS250 flywheel is shorter than the stock one, the bolt doesn't quite sit flush up against it before bottoming out in the threads on the crankshaft. I picked up a few locking washers which I hope will alleviate the problem, because I'd rather not be cutting the screw.

Haven't checked voltages yet from stator/battery to confirm proper charge.

Here is what the ignition rotor is doing:
http://www.youtube.com/watch?v=hUDWhU-yUOA

did you get rid of that dent ,cause that is not right.may be a bent bolt or not sitting right.Must check mine with out the cover.

The indentation is on the back of the ignition pickup, from the pin that keeps it from spinning freely. I'll take a picture later.

Well the washer did not work as I had hoped it would. Unfortunately after the first 15 minutes of riding around my local neighborhood turning off the bike and starting it to make sure it worked, I heard that familiar whine of the starter whirring up, but not turning the crank. I pulled everything apart (must be the 5th time by now), and click the starter button, everything moves, but it's not secure on the crank thanks to that screw.

Basically, I pulled the flywheel bolt, chopped off about 3mm (6 threads), and torqued it back down (put a penny inbetween the gears in order to tighten all the way). I've got my fingers and toes crossed that this will serve me better, so far it has.

Rode down to radioshack to pick up a fuse for my multimeter, I need to search on how to test the stator. I putzed around my neighborhood (within pushing distance) for about 45 minutes, and I haven't seen any loss of electricity, headlight doesn't dim when I use brakes or turn signals (although those are LED now, so there isn't much draw on the system anyway).

I'll have pics of my ignition advancer, bike, and numbers from the stator within the next couple of days.

Rode downtown today and parked it for an hour. Everything still working perfectly. I've been toting around a 17,19, and 8mm sockets and wrenches just in case I need to pull the case half again to tighten down the rotor bolt. Still haven't gotten the electrical figures yet, but I've been riding 2 days, so I'm pretty much convinced it's at leas partially charging.