I'm putting a 2007 motor in my 2008 frame and was wondering what a comprehensive list of items/parts would be to do this right.  I already have the tools and I pulled out the old motor. The motor is approximately 5k miles.  So far what I've got on my list...

1. Oil filter + gasket + oil plug washer
2. 3qts 10W-40 + maybe a bit more to flush the old oil.
3. Fuel filter - does anyone have the part number?
4. New air filter(s) - was thinking of going lunchbox  to save the hassle and space but will I need rejetting/tuning immediately or can I wait off on that?
5. Gas (duh)
6. Some sort of top end cleaner to clean up any old deposits.
7. New front sprocket + clip (there's a bit of notching in the sprocket).
8. Couple cans of carb cleaner to shine up motor, degunk under sprocket cover + clean out the hole where that clutch rod goes into.
9. New spark plugs - which ones recommended and what gap?  Take into account the possible rejetting/lunchbox/future exhaust?
10. Chain lube (chain and rear sprockets are good off of the original bike).

The bike also has an aftermarket handle bar and the clutch lever, when pulled all the way in, doesn't line up properly... need to figure that one out.

3. I don't think the GS comes with a fuel filter, you just put it inline after the petcock. At least on my '96 that's what I had to do. Here's the wiki page on it, http://wiki.gstwins.com/index.php?n=Upgrades.FuelFilter

9. You can always go with iridium plugs if you want to spend extra, but normal ones should be fine. I'd recommend staying with NGK. Spark plug gap should be 0.8-0.9mm. Here's a guide from the wiki http://www.everydayriding.org/2011/06/gs500-spark-plug-replacement.html

The fuel filter is probably the tank petcock itself. Swapping to a lunchbox filter, you should rejet right away (especially if the carbs aren't mounted!). Don't use carb cleaner on painted surfaces. It can dissolve paint. Stock spark plugs will work just fine (but buy whatever makes you happy). And if you are getting a new front sprocket, the rear sprocket and chain need replaced as well - they wear out as a group.

Thank!  The front sprocket is from a different engine than the chain/rear. I may just take the one off of the bad engine that appears to match the wear on the chain and rear (barely any wear, if any).

Youre going to need a floor jack to take out and lift up the new engine unless you are really really strong. A second person helps too! That tab by the horn is a MoFo when trying to get the engine to clear. Also, take the valve cover off to get the old one out and the new one in

Engine already came out... didn't need to take the cover off.  I know the tab you're talking about, but if you rotate the engine counterclockwise (when looking from the top), then pull the bottom out first, it makes it 100x easier. We figured this out after about 10 minutes of jiggling it around. My buddy helped and a floor jack did too 

Here's a pic my gf took of us right before it came out... notice the counterclockwise rotation from the top and how we're pulling the bottom part out first.  This should give you the tab clearance you're talking about.  Thanks to Harbor Freight for a great $70 1.5ton low profile jack.

Ive done 3 swaps. I know exactly how much of a PITA it can be 

Quote from: weedahoe on January 27, 2013, 09:17:47 PM
Ive done 3 swaps. I know exactly how much of a PITA it can be 

Your frame come off on the right side?

All GS are the same. The RHS of the frame or engine cradle comes off.

Quote from: weedahoe on January 27, 2013, 09:28:29 PM
All GS are the same. The RHS of the frame or engine cradle comes off.

Thought so - try lowering an inch to clear the tabs, then rotating.  Could just have been beginner's luck 

10 minutes to install or remove an engine.
See my threads on GS500 Bike Build - there are photos there of install and removal. Floor jack or other jack with some supporting boards is all it took.