GS450/500 project Fwankenstein

7

7zark7

Been Around the Block
This is the start of my project. I bought it as a complete basket case. It was a bare frame and a bunch of boxes of parts.
But the price was right and it has a clean title.

The plan is to put an SRAD frontend and an SV650 swingarm on it with the requisit wheels. And I will be putting a GS500 motor and full wiring harness in it. I made the seat and I'll be making my own exhaust as well as several other parts.


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From what I've heard putting a 500 motor in a 450 frame is a bolt in job.....until you try and put an exhaust on it. The exhaust ports on the 500 motor are "straight" and point directly at the 450 frame's downtubes :(
 
Hillay, What about the GR 650 motor? Just curious if you would know.

Good lookin project BtW!
 
Big Rich said:
Hillay, What about the GR 650 motor? Just curious if you would know.

Good lookin project BtW!
Click to expand...

Pretty sure the 650 exhaust ports flare out a bit (like the 450) so it should be easier to fit. Not sure if the 650 bottom end is a bolt in to the 450 frame though ???

Although I have heard you can put the 650 cyls and top end on the 450 bottom end ;)
 
Ive heard about a lot of swaps with the gs / gr twins. Thank you sir! Might find a good use for that spare motor yet....
 
Be watching closely, I have a GS 250 with a spare donor bike that I am hoping to get off the ground.

Cheers
Rob
 
hillsy said:
From what I've heard putting a 500 motor in a 450 frame is a bolt in job.....until you try and put an exhaust on it. The exhaust ports on the 500 motor are "straight" and point directly at the 450 frame's downtubes :(
Click to expand...

Thanks for the heads up. I'll make sure I look into that before I do any real work with the motor and harness.
 
ferg_69 said:
Be watching closely, I have a GS 250 with a spare donor bike that I am hoping to get off the ground.

Cheers
Rob
Click to expand...

I would be interested to know if the GS500 motor fits in the GS250 frame - as the 250 frame has a single downtube there is no exhaust pipe fouling issues. I suspect the bottom ends are different though.
 
I know that the 250 AND THE 400 are the same, taking a guess I would say the 450 would be different and align more with the larger motors as mentioned above.

Without doing any research it sounds as if the 450 aligns with the 650 and the 500 is a newer design? Anyone clarify?

Cheers
Rob
 
I got some more done on the 450 and I also have some engine parts on order. I guess 500 just wasn't going to be enough so here is the plan for the motor.

GS500 cases and crank
GS500 barrels bored to accept GR650 pistons (77mm instead of the GS500s 74mm)
GR650 head and cams.

This will give me 527cc
A better flowing head and higher lift cams.
Plus I will still have the angled exhaust ports.

HUGE thanks to dgyver on the GSTwins board for all of the great info on the motor options.

I'll still be using the stock GS500 carbs until I can afford some flatslides.


As for the rest of the bike, I was able to get the front end and the swingarm mounted.

Frontend is and SRAD with a knurled SV stem pressed in. Bolts right up. I just need to figure out some steering stops.

Swingarm was a little more tricky. I had a full inch taken out of the pivot point (1/2 on each side)
Then I had to have some bushings made to fit the ID of the bearings and the OD of the GS450 pivot bolt. All I have to do now is build some points to mount the monoshock.

I will also need ot take some material off of the sprocket carrier so the sprocket will line up and not hit the frame.

I haven't decided how high I want the rear.




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Sweetness! If you cant find GR650 pistons, there's another bike that uses the exact same. I think it was FJ1200 or something? It's on GStwins as well.

Cant wait to see now this ends up.......
 
Big Rich said:
Sweetness! If you cant find GR650 pistons, there's another bike that uses the exact same. I think it was FJ1200 or something? It's on GStwins as well.

Cant wait to see now this ends up.......
Click to expand...
Thanks for the tip but I've already got them. The head, pistons and cams came in the mail today.
 
Great project!

I am a little farther along in the exact same setup. GSXR front end, Mono-rear. I just bought a GR top end and am in search of carbs and pistons. Looking forward to this one.


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scottychop said:
Great project!

I am a little farther along in the exact same setup. GSXR front end, Mono-rear. I just bought a GR top end and am in search of carbs and pistons. Looking forward to this one.
Click to expand...

That's pretty sweet! You're doing a lot more work to the frame than I am. What swingarm is that? GS500? Looks really long.

Anyway, it looks great so far.
 
7zark7,

Thanks for the compliments. The swingarm is off a Katana, linkage off a GSXR. I had a bit of machining to do also. More pics!
 
Slow progress. I've got the rear suspension almost done. It's all tacked together and I have to finish welding it. I keep forgetting to bring my camera to the shop so I don't have any pictures of that.

But I did start making my license plate and tailight bracket. Here's what I've got so far.


I still need to cut the sides a little more to get a better curve on them.
Then I can make the other part of the bracket and weld it all together.

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