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gs 500 into a 450 frame????

  • Thread starter Thread starter BIGYAM
  • Start date Start date
B

BIGYAM

Guest
Hi everyone, I'm new to the club and ive got a quick question , hopefully someone will be able to answer, I've had a gs 450 twin that iv'e been doing up as a flat tracker and it looks great but after 4 yrs of rebuild finally got it mot'd last saturday but the engine siezed on the top end, AGHHHH, so i was thinking of slotting a gs 500 engine in , All i need to know is if it will fit as they look identical, Any help would be greatly appreciated, many thanks. Nige..
 
The biggest problem will probably be the exhaust ports- gs500 headers come right out into the 450 frame. I believe the 2 motors have the same outer dimensions, so it may fit fine otherwise.
 
Thanks for the quick reply, Hmm thats a tricky one to solve, Once again Thanks
 
yes they fit, but you need to have new exhaust headers made for you. alternatively you can buy a box of mandrell bends.

I have a photo somewhere here...

IMG00078.jpg


you are warned now, this bike caused injury to everyone that had a ride, including the owner who took a handle bar in the chest. we called it the weapon and it was dangerous. also stupid amounts of fun.

The builder was OldSchoolOrange. he had a thread about this in 2008
 
Wow...Just wow. Nice. Also hate to jump thread here....but does the tranny 450 tranny fit the 500? I might be going this route.
 
Thanks all, I'll seriously look into this now !!!! I'm starting to get excited now
 
i think the bigger engines will go in a 250 frame but not the other way round. 250's have a single frame down tube that won't foul on the headers.
 
500 into 450 frame job done

500 into 450 frame job done

:) Hi all, just a line to let you know how i got on, the 500 did go in the 450's frame with very little messing about, It now runs 98% sweet just has a little flat spot at about 80mph then takes off again to nudge the ton:lol: so i've still got a little tweeking to do but it starts stops and handles great, getting braver every day. the main alterations were :- (1) re-fabricate the exhaust headers to miss the frame. (2) realign the front and rear sprockets. (3) Mount the black ignition box and swap to 500 coils. (4) had to use various cables from the 500 e.g. clutch throttle and choke, also had to fit a handlebar choke lever,
Next job is to alter the gearing as the 450's rear sprocket is a lot larger than the 500's so it should cruise along the m-way faster and lower revs.
Overall i'm really chuffed with the bike glad i did it now. Nige:) i'll put some pics on asap
 
Good effort! Are you able to get some close ups of how you routed the headers around the frame? That seems to be the trouble point for this swap...
 
Very nicely done.
I like the way you had the pipes bent to clear the frame tubes and the scrambler type look of the exhaust on one side.
We need more details on that exhaust system. ;)
The bike looks great!


welldone.gif


Daniel
 
Very cool! I may consider this swap since parts for a GS450 engine are getting a little harder to find. Wouldn't mind upgrading to GS500 electrical either! Can you please get more pictures of the headers?

Good job :).
 
Hi, if you check my albums out iv'e posted some more pics of the headers on there, please excuse the welding on them as i tack them in position at home with a M.M.A. set then take them to where i have access to a T.I.G. welder to make a nicer job of them as the MMA set tends to blow holes in the pipe.
Eventually im going to fab some more using larger diameter pipe as i think these are now restricting the 500 engine slightly, All the best Nige.
 
Mate that looks great, you've done well to get those pipes routed like that, doesn't look like they're too tight a radius to affect it either.
 
BIGYAM,

Good on you for finding a solution to the 500 engine in a 450 frame delemia. Many of us Pint'ers have wondered about what could be done. Are the pipes made from stainless? Once the final welds were done they look real good. I understand about blowing holes through the steel with the wrong type of welder. I stepped up from a stick welder to a MIG about 15 years ago, and what a difference. I'm still just a carpenter who melts steel, compared to a real welder. Tastefully done bike you have there and good choice on the "Fast Blue" color.

One of the things I like about this forum is chating and see bikes from all over the world and I understand about privacy concerns, but can give us a general idea where you are? Yorkshire? Cheers!


Charlie G
 
Hi all, thanks once again for all your kind comments,
Yes the pipes are stainless and the welds are not as neat as i would have liked, being a tig welder by trade, but trying to weld over the stick welds is tricky even after grinding them out, throw into the equation a few gaps and carbon soot on the inside of the pipes and it gets a little trickier , But i suppose they've not turned out bad.
As for area i live in I,m Derbyshire born and bred But now live just over the border in Nottinghamshire( Robin Hood country)
I made the pipes out of a set of headers which i got off of e-bay brand new from a company called Motad. Every now and then they sell off discontinued stock , i got four brand new header pipes for about ?30 Bargain they were "black chrome" but it polished off ok with some emery cloth and the old polishing wheel. the beauty of this is you've got plenty of bends and straight bits to play with. as opposed to buying each individual bend if you mess up you got to buy another, Cheers Nige
 
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