450 engine rebuild

[Big Rich]

Pete, the shaft diameter on the CCT from the 500 is much larger. The 450's CCT might bolt into a 500, but not vice versa.

[pete]

Bugger, that'd be right Rich... I'll just have to do the 500 cylinder conversion then

Maybe one day...

[Mekanix]

You can use this one on either block I believe.

http://www.ebay.ca/itm/MANUAL-CAM-CHAIN-TENSIONER-89-00-SUZUKI-GS500-E-F-90-91-92-93-94-95-96-97-98-99-/140904106503

But really there is no need. The one for the 500 Rarely ever fails.

[pete]

That's ok, I'll stick with the auto one...

[phillipjohnw]

Sorry Pete, mekanix is right. I just ran to the garage to double check.

Haven't had anymore time to work on the bike though.

[phillipjohnw]

Sorry its been a while guys. Life keeps getting in the way. Anywho here are some pics to keep you drooling... or something.

Pretty far away, but I have the top end mock built and am in the process of timing it. Any tips would be great.


Rattle can job on the tank. Its not professional, but I dig it.

The picture makes it look orangeish, but its more of a red sparkle.

I am thinking of sanding some of the red off to have it more black with a hint of red.

I just felt I needed another caption.

[Mekanix]

it times exactly like it says in the manual.

you might find it easyer to get the right cylinder to top dead center and then set the exhaust cam in place so the # 1 points forward but you won't be able to tighten it down.

just keep tension on the chain and rotate the whole crank and camshaft backwards half a turn and the exhaust cam will drop in place. then you can tighten it down. then install the intake cam by counting the link pins between the #'s 2 and 3 and then drop the intake cam in. tighten it down and release the tensioner.

You should be able to rotated back to tdc and they should be aligned or within 1 tooth, just repeat until its lined up.

[phillipjohnw]

Well things were going awesome on the bike. Got everything torqued down and timed up. Tonight was looking awesome, all the way until one of the journal bearing bolts snapped. Once again I'm stuck.

[phillipjohnw]

Well got a bolt at home depot, hope the high grade metric bolt holds up.

Having a bit of computer issues uploading the pictures, but I took one of the finish product. Now I just need to get it in and tuned up.

[pete]

As long as it's a suitable strength bolt you should be good... not sure how all that works though...

[Mekanix]

Grade 9 i think it is.

[phillipjohnw]

Possibly, I don't know the metric grades that well. It was the most expensive one with M6 threads. Other than that the bike is coming together. Trying to tie up some other small projects (literally I'm trying to tie the wiring out of the way) Hopefully getting the motor installed tonight/tomorrow. And finally a picture.


I know its not a motor, but I love this paint job!

[phillipjohnw]

Well the motor is in. Trying to tidy up the wiring. I posted in the electrical section, but heard nothing back yet about how to hide the rats nest that is the harness.

[pete]

Nice work mate... will check out your electrical post when I find it...

[jeffasaurus2]

Quick question, for this conversion have you used the 500 cams you had ordered? Or have you stuck with the 450 ones?