Suzuki 650 Motor Exchange

[DeanGS650G]

I have a 1981 GS650G that has a bad motor (the motor is apart and I am not sure what is wrong). My question is will another motor bolt into my 650G frame (like a 650GL or a 850G motor). I did search and could not find my answers, so if this has been addressed before, I apologize.

Any help is greatly appreciated,

Dean

Elizabethtown, KY

[brveagle]

the only motor that will without modification is another 650 motor...

and then that is has to be the same drive system. I.e. you can't swap a shaft motor into a chain bike

[themess]

Who took the motor apart?

Do you have all the parts?

What was wrong before the motor was disassembled?

G and GL motors are the same.

[DeanGS650G]

The motor was taken apart by a Suzuki mechanic. It had a ticking and lost all power. I have a large box of motor parts and as far as I know all parts are there. I was informed that the cost to fix the motor would be approx. $400-500. At that time, I did not have the money to fix the bike so, I parked the bike. I am trying to get the bike back on the road, but I cannot remember what the mechanic said that was wrong with the bike and they have no copy of the repair bill. The bike has been sitting for 7 years now and I figured putting in another motor would be the quickest fix.

Thanks for the replies.. Dean

[themess]

I've never disassemblef a bike motor, but I've done two car motors. I'm guessing that most mechanics can spot severe problems, ones that would have it lose all power, pretty quickly. And, it seems, most of those problems don't require rebuilding the motor, but are in fact problems with carburetion and electrical systems. If it were my bike, I would likely start with the shop manual, and or the fiches (exploded diagram of every part in the bike, along with part numbers and names) available from Alpha Sports and Bike Bandit.

http://www.alpha-sports.com/suzuki_parts.htm

and lay out every single part, on the garage floor, in the order of he fiche. Then I'd get some solvent (like Gunk Super Concentrate mixed in kerosene) and a parts brush and clean them. And while cleaning, I'd look for cracks, abrasion, and obvious wear. I'd check off every part as I found it, down to the bolts and nuts. Should take a Saturday morning, or a bit longer.

Next I'd try to find some nice person who's worked on the engines from early 80 bikes and ask him to look at the parts, and see if there's any problems that I couldn't find. If neither of us could find any big problems, I'd start to put the engine back together, slowly and carefully.

I'd price replacements for damaged parts.

There just aren't that many engines out there. You'd be looking for a recently crashed bike where the engine wasn't damaged. Look on Ebay, and set up an automatic search that would report all 650G and 650GLs that come up for sale. You might find some parts bikes before they have been taken apart.

The other possibility is to turn it into a parts bike.

We you the owner when the bike stopped working properly? How many miles? How long had you owned it?

[DeanGS650G]

Thanks for the information. I was the 2nd owner of the bike and rode it for three years before the motor developed a tick and ultimately lost all power. The motor had 15,000 miles on it when it was taken apart.

[duaneage]

Sounds like a valve adjustment problem, might have been easy to fix but there is no telling what is wrong now. if you like the 650 shaft drive bike get another one and come up with a good bike from the two. Ultimately you might end up just parting it out for fun and profit.