81 Suzu GS450 Big-Bore Question

CupidsDeathDay

Been Around the Block
From my reading and understanding of doing a bore increase, the rule of thumb is stated as a minimum 0.003-0.0035"(0.0762-0.0889mm) over the size of the piston, for any bore sizes between 2.500"-3.625"(63.5-92.075mm). The 81 GS450 manual says it's 71mm piston/bore size, but doesn't give me exact for either/or.

So if I get 73.5mm aftermarket Suzuki replacement pistons, that would put my total recommended bore size at a minimum of 73.5762mm. I figured I would round it to maybe 73.580-73.6mm on the bore size, as it's a little under the midway point between the recommended minimum of 0.003"(0.0762mm) and max of 0.005"(0.127mm), to leave room for "error". Does that sound about right?

I just want to be sure I am calculating this correctly.

Any input would be appreciated!
 
Take your cylinders to the machine shop before investing in pistons. The stock bore is likely to be out of round and may even have a taper. The machine shop can also inspect for cracks in the liners and/or the actual aluminum cylinder.
 
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