Quote from: Daeouse on January 05, 2016, 02:01:12 PM
Looking good!

Appreciate it. 

Quote from: Big Rich on January 10, 2016, 11:08:06 PM
Ah, ok. I've done a little Dremel work before and it kills my hands after a bit.

But anyways, here's what I recommend for the engine: Use OEM gaskets wherever possible - cheaper aftermarket ones tend to weep oil. The base gasket can't be reused, nor can the head gasket. Those copper washers under the cylinder stud nuts should be replaced too. I can't remember - are you using the original tachometer? If not, the tach drive gear is easy to take out while the engine is apart. I saw you mentioned new valve seals (good idea), but I'd spring for new carb boots along with the orings that fit under them. After 13 years, you just don't know what has dried out.....

I think everything else is pretty well covered by the service manual. If you reuse the piston rings, measure the gaps first and look into getting a quick hone on the cylinder walls. May as well do it once, right?

Thank you Rich, I greatly appreciate the advice, Ill be sure and replace all of those things. If its worth doing, its worth doing right

No problem man. Just thought about it - there are some other orings that need replaced. Number 9 in this diagram:

http://www.partzilla.com/parts/search/Suzuki/Motorcycle/1998/GS500E/CYLINDER+HEAD/parts.html

Some engines have them (GS500 for instance), and some don't. That's why I forgot about them earlier.

Ok, so I've gone through most of the steps with the POR-15 kit, haven't lined it yet though. Let me say this, what a pain in the fuc#in ass! Who ever owned the bike before must of used a tank liner, unless these bikes came with a lined tank, which I've never heard, they did a shaZam! job. I got most of it out, then realized I could see a big chunk still stuck in there, so I had to use a coping saw to pry it out, and then the chunk was so big that it wouldn't fit through the fill hole. I had to put a screw through it and pull it up to the fill hole, then drill it out until it was in enough pieces to pull out.
The amount of rust and old liner I've got to come out is staggering. I have a few dent to pull then I'll do a final acid wash and coat it. Here are a few pics.

 

That sounds like it sucked!!!

Bravo for all your hard work!

Well more updates, I cleaned the engine up, getting ready to give it a fresh coat of paint soon. If you've never cleaned an engine before you might not realize what a pain in the ass it is, I just try to go zen and focus on a little bit at a time, it actually becomes enjoyable. Anyways, here are the pics.

 

Damn that looks good!

After I wore out a toothbrush and used many rags and Qtips, I wiped it down with acetone and taped it up for primer. Haven't primed it yet, hopefully this week.

Quote from: Daeouse on February 16, 2016, 10:31:04 PM


Damn that looks good!

Thanks man, I appreciate your comments. I'm looking forward to following your build.

Forgot to add I also scuffed it with a red scotch brite pad

Yikes! How bad are your hands cramping up? I polished a lower end once...... and never again.

Since you're painting the engine, wouldn't it have been easier to leave all the covers on (oil pan, oil filter, etc), paint over everything, then just strip the paint off the covers once removed? Either way, good work as always Mr Fink.

Edit: Nevermind.... I just remembered about your rad sketching on the other covers. Carry on!

Quote from: The fink on February 17, 2016, 01:38:38 AM

Quote from: Daeouse on February 16, 2016, 10:31:04 PM


Damn that looks good!

Thanks man, I appreciate your comments. I'm looking forward to following your build.

Always glad to offer praise when it's due!

Build thread link is in my sig. 

Quote from: Big Rich on February 17, 2016, 01:57:33 AM
Yikes! How bad are your hands cramping up? I polished a lower end once...... and never again.

Since you're painting the engine, wouldn't it have been easier to leave all the covers on (oil pan, oil filter, etc), paint over everything, then just strip the paint off the covers once removed? Either way, good work as always Mr Fink.

Edit: Nevermind.... I just remembered about your rad sketching on the other covers. Carry on!

Thanks Rich. It was a lot of work for sure, but I know the end result so it keeps me going no matter how tedious these things become.
As for the covers, well, you'll have to wait to see those, they are powder coated, I'll post pics of them soon. Thanks as always Rich. 

Spotless, well done, will be cleaning my engine thoroughly this weekend and then repainting in coming weeks, stuck on colour though, any idea what colour you're going for?

Quote from: baronduff on February 25, 2016, 02:27:48 PM
Spotless, well done, will be cleaning my engine thoroughly this weekend and then repainting in coming weeks, stuck on colour though, any idea what colour you're going for?

Thanks man, I'm painting the engine black, with the exception of the side covers and valve cover. I'll post more pics soon. Good luck doing yours. 

have to say theres so many details i just don't like about the build but nonetheless you're really putting the time in and it shows, keep the good work up man!  

Quote from: iamhiding on March 13, 2016, 05:05:40 AM
have to say theres so many details i just don't like about the build but nonetheless you're really putting the time in and it shows, keep the good work up man!  

um....thanks i guess...

Ok so here's a bit more. I had the side covers and valve cover powder coated, the color is copper vein. The pictures don't quite do it justice, but here they are.

  Holy sweet Suzuki-riding Jesus! Amazing work!!!

Quote from: Daeouse on March 27, 2016, 12:18:35 PM
Holy sweet Suzuki-riding Jesus! Amazing work!!!

Lmao! Thanks man, I appreciate it, I'm getting anxious to get things done. Thanks for following along!