Gs500F topend on Gs450 1982 bottom end

[prichmon]

I recall reading articles of guys installing 500 tops on 450 bottoms. I can't seem to find the articles.

Other than pistons and jug is there anything else I need? 450 or 500 gaskets? 450 valvecover, head, valve cover gasket. 500 base gasket?

Thanks all;

Rich.

[LAB3]

When I looked into it things where the other way around with a 500 bottom and 450 top. From what I've read the 500 bolts right into place but the exhaust outlets on the 500 heads get blocked by the frame which is why a 450 head is necessary. If you're looking to put a 450 lower into a 500 frame you'll want to keep that in mind, it's the exhaust outlets that make a difference.

[prichmon]

I'm attempting to do a big bore with suzuki parts on a 450. I have parts from a 500 with a bad bottom end. I thought other had put a 500 jug and pistons in a 450 making a 487.

Thank for the reply.

RR

[LAB3]

I'm attempting to do a big bore with suzuki parts on a 450. I have parts from a 500 with a bad bottom end. I thought other had put a 500 jug and pistons in a 450 making a 487.

Thank for the reply.

RR

In that case it should be easy to measure the length (height) of the 500 jug compared to the 450.

[prichmon]

I found the post in another forum and it appears the author used GS450 Head gasket rather than the 500. The 500 is ~.011" vs .044" for the 450. On cruizinimage they offer a big bore 450 gasket which I ordered to get a better diameter for the oversize pistons. Assumming the 500 and 450 base gaskets are mechanically identical. The 450 base is ~.009" thicker to give more clearance for the pistons.

[grcamna2]

I recall reading articles of guys installing 500 tops on 450 bottoms. I can't seem to find the articles.

Other than pistons and jug is there anything else I need? 450 or 500 gaskets? 450 valvecover, head, valve cover gasket. 500 base gasket?

Thanks all;

Rich.

Rich,I also have a GS450 which I want to install a GS500 set of jugs and good pistons;I plan to use the GS450E head.
I'm researching which piston choice I can find;ideally a 75mm big bore set of pistons made for a GS1000..
Do you have a link to the the other post/forum? I thought the person did the 450 to 500 swap on this forum?

[prichmon]

I used stock GS500 pistons and jug. GS500 base and cruizin image head gaskets. I just got the bike running this weekend. I have had a stock 450 and the franken 450/500 running side by side and the 450/500 sounds like it has significantly more pressure. I don't think I'll get the 450/500 done this coming weekend since I'm waiting on some suzuki oem parts to arrive for the rest of the bike.

Cruizin image also offers a 480cc BB kit for $180. the gs500 is 487cc. I had a gs500 at one time and the engine snapped a rod and locked. I have been fortunate the cylinder and 1 piston didn't have any issues. I spent ~ 120 on rings, 60 on gaskets(aftermarket), 50 on another used piston and 150 honing and having a shop go over the head.

If I had it to do again I would probably do the BB kit from cruizin image.

Good luck grcamna2.

[grcamna2]

I used stock GS500 pistons and jug. GS500 base and cruizin image head gaskets. I just got the bike running this weekend. I have had a stock 450 and the franken 450/500 running side by side and the 450/500 sounds like it has significantly more pressure. I don't think I'll get the 450/500 done this coming weekend since I'm waiting on some suzuki oem parts to arrive for the rest of the bike.

Cruizin image also offers a 480cc BB kit for $180. the gs500 is 487cc. I had a gs500 at one time and the engine snapped a rod and locked. I have been fortunate the cylinder and 1 piston didn't have any issues. I spent ~ 120 on rings, 60 on gaskets(aftermarket), 50 on another used piston and 150 honing and having a shop go over the head.

If I had it to do again I would probably do the BB kit from cruizin image.

Good luck grcamna2.

I appreciate the feedback on how it works for you.
I'm considering getting in touch with JE Pistons for them to build a pair of 74.25mm(my STD size 74.00mm GS500E cyl. liners are in good shape)custom pistons;I want to match the crown shape and height of the original stock GS450 pistons.

edit: how did the cam chain tensioner work out on your build ?