Hi,

as my front engine mount is shot was looking for another lower crank case. Found one which is from 2007 bike. Mine is 1992. Will the guts
fit in the newer case? are the silver engine parts ( lower-upper crank case and barrels)  interchangeable with the black one?

cheers,
Lauri
1992 GS500E

I believe that the cases come as a matched set--best to replace both.

you have to replace both halves.

Along with bearings- you WONT be able to re-use the bearings in there! DONT EVEN THINK ABOUT IT, the only bearings you can get away with is the 2 ball bearings, and the connecting rod bearings [assuming they're still within spec.] the balancer shaft bearings and crank will for sure need to be matched, and replaced.

if you're in it for the adventure. Good luck. its gonna get pricey. [$500+ for parts alone]

if you're in it for just getting back on the road. buy a new engine. [$500 for an engine]

Also you can't swap a newer lower end, because of the oil cooler and stuffs. unless of course you get those bits to add.

If you've got questions or need some pro-tips. feel free to ask, I personally just finished mine like a week ago.


I'll start off with a free pro-tip. get a JIS screw driver set, and ANY Philips head looking screw thats inside the engine, just SMACK it with heat, lots of friggin heat, like pretend you're trying to melt the bolt itself. Suzuki decided to use cheese grade bolts, and slap some gnarly loctite all the way up the threads... once you think you've loosened the loctite, I put the driver bit into a hand drill [the one I use for boring 1 inch holes in 12+ inches of timber] pushed all my body weight into it, and gave it a squeeze, and pray it comes out without ripping the bolts to shreds. [I got 1 of 3 in a particular spot] - this was before I knew suzuki was playing the "lets waste loctite" game.

right. so do i understand correctly i cant use my original big end bearings with the new crank case even though the crankshaft stays the same? Lets say i will get both upper and lower cases.

Not worried about this job being overly complicated as have had my engine apart already for gearbox swap. The cost of it.. upper and lower end approx  £100 plus a gasket set. if it is going to be big end bearings as well.. And to do it only to get the engine mount sorted Any ideas how to get the front engine mount fixed without all this ?

Cheers,
Lauri

Quote from: Sahtlinurk on December 15, 2017, 10:20:28 AM
right. so do i understand correctly i cant use my original big end bearings with the new crank case even though the crankshaft stays the same? Lets say i will get both upper and lower cases.

Not worried about this job being overly complicated as have had my engine apart already for gearbox swap. The cost of it.. upper and lower end approx  £100 plus a gasket set. if it is going to be big end bearings as well.. And to do it only to get the engine mount sorted Any ideas how to get the front engine mount fixed without all this ?

Cheers,
Lauri

Rachet straps hold everything....

Right, okay there's code stamped on the rear of your engine, says A or B, there will be code stamped on your crankshaft, it says A, B, or C. you compare these two to their respective locations. to get the right sized bearing. so saying on the rear of the engine reads A, and the one on the crankshaft says C. you need a "brown" bearing. so you look and it gives you a part number, (12229-01 DOO-OCO) would be your Brown bearing for that set. its all in the manual.

So here's what you can re-use.
The Two main ball bearings, "big bearings"
The Connecting rod bearings.

The rest of the babbit bearings have to be replaced both that contact the crankshaft and the balancer shaft. A total of 12, Remember when you place an order for the bearings themselves, they don't come in sets [stupid I KNOW, WHO NEEDS ONE HALF OF A BEARING?!] but replacing all 12 bearing shells. is $105.36 USD not cheap...

cheese grade bolts - cracks me up everytime