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Search results

  1. W

    GS400/500 Gr650 Hybrid engine

    Very nicely done! I don't even consider it "build", it's purely for looks. This GS500E is gonna be a fun backroad bike, nothing serious about it. But I understand your sentiment, to be honest, the whole thing was an experiment, I wanted to see what this idea would look like. I have run into...
  2. W

    GS400/500 Gr650 Hybrid engine

    A small update on the GS500 guys, mostly as a proof that I'm still alive and working on this, and as a distraction from the fact that NOTHING has happened with the hybrid engine of late. I promise, progress will be made this year, I just want to get this GS500 out of the way first :). I did a...
  3. W

    GS400/500 Gr650 Hybrid engine

    Thats a good plan, Can I follow your progress somewhere?
  4. W

    GS400/500 Gr650 Hybrid engine

    True, but that issue is mitigated with custom pistons. Hence, why I said "if you are going to source custom pistons". I take it, "custom pistons" means having them made by CP Carillo or equivalent.
  5. W

    GS400/500 Gr650 Hybrid engine

    Welcome! The stock GS500e pistons should fit that motor, or do you plan to increase C/R ratio as well with custom pistons? It's a real PITA that the exhaust exit angle is different on the GS500 heads, otherwise you could have used those. If you are going to source custom pistons, might as well...
  6. W

    GS400/500 Gr650 Hybrid engine

    Small update. I received the parts I ordered. I got SKF IR 28x32x20 bearing races, they will have to be modified. Two oil feed holes will need to be drilled, as shown in the drawing below. It's hard to measure accurately but they should be spaced 88 degrees apart from each other. Diameter of...
  7. W

    GS400/500 Gr650 Hybrid engine

    The stud spacing has already been modified on the crankcase Chuck!, maybe one day I'll restore all the photo's in this topic but for now take my word for it. It involves machining aluminium plugs that are screwed into the stud holes using the strongest epoxy glue one can find and then...
  8. W

    GS400/500 Gr650 Hybrid engine

    Progress! During the last couple of days I took the time to create some tools to press both the GS400 crankshaft and the GS1000 crankshaft apart. I made some exciting discoveries. See the drawings below for what you need to make to press it apart. And here is the final product with the...
  9. W

    1981 Suzuki GS650G - dies under load when throttled past ~1/3

    Your remarks regarding the weird pilot screw, replaced screws, possibly replaced boots makes me think chances are high the PO has messed up a carb rebuild. I still think you should start with a proper compression test and then move on to a full carb rebuild. stop messing about and do it once...
  10. W

    GS400/500 Gr650 Hybrid engine

    I have looked through multiple catalogues to find fitting rods for the GS400 crank, no luck. I also have a preference to use OEM Suzuki parts, hence the GS1000 rods. I managed to find a GS1000 crank for about 110 euros, which will yield me 4 rods, 6 bearings, 8 rod washers. Figuring it's not...
  11. W

    Valve shimming and tuning (GS450E)

    Good stuff, have you managed to put the bike together in the meantime? I'm based in the Netherlands and have a lot of shims on hand, postage within Europe is just 15 euros I believe. About the popping...do you have stock airbox installed? The OEM CV carbs do not work well with pod filters and...
  12. W

    1981 Suzuki GS650G - dies under load when throttled past ~1/3

    You've done a great job troubleshooting the issue so far. Assuming the ignition is really alright, I'd say do a compression check first before you spend hours and hours fixing the carbs. Do a test in cold and warm condition. If compression tests OK then I'd say there is something wrong with...
  13. W

    Does Suzuki GS450 tachometer fit and work on a GS650GT?

    If you are still looking, here you can buy a brand new one for your GS650GT: https://www.cmsnl.com/suzuki-gs650gt-1983-d-e01-e02-e04-e06_model13488/tachometer_3421034560/
  14. W

    Speedmoto VM30 Kit

    The stock CV carbs run horribly with K&N pods, the diaphragms in the OEM CV carbs need smooth laminar air flow into the carbs to get a good reliable vacuum signal. It works after some fidling around, and some people say they run fine...I don't believe them at all. I have had pods on a stock...
  15. W

    GS400/500 Gr650 Hybrid engine

    Small update, I have decided on the way forward and have ordered the parts. I'll be using GS1000 con-rods on the GS400 crank, the challenge here is the difference in big-end size. GS400 GS1000 Stroke 60 64.8 Crank Pin 28 29...
  16. W

    GS400/500 Gr650 Hybrid engine

    Forget about everything I said below, I did some more thinking and although it would be possible to modify the GS500 crankshaft, the real issue is the big-end plain bearings. Mixing roller and plain bearings is not a great idea because of the needed oil pressure towards the plain bearings. I...
  17. W

    GS400/500 Gr650 Hybrid engine

    Small update regarding the hybrid engine, I went and picked up a bottom end for 25 euros, a steal! The seller had a lot of stuff so I got myself a whole bunch of seals, o-rings, and gaskets. Also I got a bin full of nuts, bolts, washers, 2 crankshafts including their balancer shafts and some...
  18. W

    GS400/500 Gr650 Hybrid engine

    Update 2 I wanted to make the rear swingarm look a bit more aggressive, the GS500 rides amazing with an USD front fork and doesn't really need any bracing in the rear, so this is purely for looks. I started out by drawing the brace on a piece of paper, cut it out and stick it to a rectangle...
  19. W

    GS400/500 Gr650 Hybrid engine

    In the meantime, I will post some photo's here of another project I am working on. It's a GS500e that I am completely rebuilding: The idea is: Modified frame (mostly for looks) Shortened custom seat KAWA ZX-9R front fork Ducati monster front fender Stock engine but powdercoated and looking...
  20. W

    GS400/500 Gr650 Hybrid engine

    Good to see you still active here Chuck, you enthousiasm is well appreciated! as to your questions, A lot of the details have become blurry and I don't remember. I've been through some dark times in the last 4 years and a lot of this stuff has been pushed out of my mind. I don't remember if the...
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