SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> top dead center /cgi-bin/YaBB.pl?num=1168453681 Message started by franch on 01/10/07 at 10:28:01

Title: top dead center Post by franch on 01/10/07 at 10:28:01 so after doing the cam chain i had trouble finding TDC i followed advice from here and lined up the 2 marks on right side of camshaft end to top of head, and put the gear on so that the pin was positioned at 1 oclock. i had noticed that on the rightside crankshaft end the is a small punchmark. should that have been facing towards the top ? also i did the plug cap fix and she is still leaking from that same area. there is a big head bolt back there that you have access to when plug cap is removed. does that head bolt have a sealing washer ? or am i possibly looking at a head gasket failure ?

Title: Re: top dead center Post by vroom1776 on 01/10/07 at 11:21:56 these should help, left click to view image, then click on it again to enlarge http://www.bikebandit.com/partsbandit/assets/schematics/Suzuki/SU0145_004.gif http://www.bikebandit.com/partsbandit/assets/schematics/Suzuki/SU0145_003.gif

Title: Re: top dead center Post by Greg_650 on 01/10/07 at 11:39:06 franch wrote: so after doing the cam chain i had trouble finding TDC i followed advice from here and lined up the 2 marks on right side of camshaft end to top of head, and put the gear on so that the pin was positioned at 1 oclock. i had noticed that on the rightside crankshaft end the is a small punchmark. should that have been facing towards the top ? Whoa...Up to this it sounded about right.  The right side crankshaft mark?  What about the line and paint mark on the left side crankshaft?  The bolt head under the plug. You might want to take a look back at the Tech section Quote: also i did the plug cap fix and she is still leaking from that same area. there is a big head bolt back there that you have access to when plug cap is removed. does that head bolt have a sealing washer ? or am i possibly looking at a head gasket failure ? Did you seal the plug? And yes...I mentioned it somewhere that those copper washers are meant to squish and seal, but if you can't find TDC, it isn't running yet is it?

Title: Re: top dead center Post by franch on 01/10/07 at 15:43:38 yes i sealed the plug with permatex copper. yes i marked the left side crank notch with notch in left cover. yes it is running but like crap and thats how i see the wet spot beside the exhaust.

Title: Re: top dead center Post by Kropatchek on 01/10/07 at 15:54:12 The correct sequence is: first TDC then align the marks on the camshaft. If the camshaft is not connected to the crankshaft it does not matter which TDC. TDC is TDC.  Once you align the camshaft you time the opening (and closing) of the valves. ;D Put the piston at TDC Align the marks on the camshaftgear. You're done. Greetz Kropatchek

Title: Re: top dead center Post by franch on 01/10/07 at 19:45:51 now that makes sense. thanks all ! Looks like I'm going back in to double check TDC and to find that leak ! can I do any damage by just removing the head bolt that lies under the plug cap and replacing that compression washer ? or will the head warp or gasket become comromised ?

Title: Re: top dead center Post by Rockin_John on 01/10/07 at 20:49:42 franch wrote: now that makes sense. thanks all ! Looks like I'm going back in to double check TDC and to find that leak ! can I do any damage by just removing the head bolt that lies under the plug cap and replacing that compression washer ? or will the head warp or gasket become comromised ? I eagerly await other’s answers to these questions of yours, as I’m due to wade into the same swamp in the not too distant future. Like you, I suspect leaking at both the plug and perhaps the underlying bolt's washer/gasket too. It’s hard to tell exactly where it all comes from back there in that recess behind the header. Good luck with yours!

Title: Re: top dead center Post by Greg_650 on 01/11/07 at 11:18:34 franch wrote: now that makes sense. thanks all ! Looks like I'm going back in to double check TDC and to find that leak ! can I do any damage by just removing the head bolt that lies under the plug cap and replacing that compression washer ? or will the head warp or gasket become comromised ? You did thoroughly clean and seal the headcover to the head, right? You can probably safely remove the one nut when the engine is cold, but I'm kinda having doubts about that for the leak.  Really. http://i21.photobucket.com/albums/b277/gmdinusa/CylinderNut01web.jpg

Title: Re: top dead center Post by franch on 01/11/07 at 18:21:06 Yeah, she was clean as a wistle. used permatex copper there too. my buddy helped me guide the head cover back in place while I manuevered the 2 bolts that stay with the head cover so that we didn't inadvertently smudge any sealant off. it definitely appears to be leaking in that area you show in your pic. I had spent lots of time scraping of old oil sludge and road grime from there with a dental tool before putting it back together. maybe, just maybe its old oil that got heated up and is spreading. never got a chance to hit the car wash. also noticed it's already pooling in there. having taken the head cover off once I am not too shy to do it again, wasn't that hard just time consuming. I'm going to move her back in next to the woodstove and do it all over again including that compression washer.

Title: Re: top dead center Post by sparkett on 01/12/07 at 04:40:17 dont forget to check that little o-ring, they sneak out and get pinched. or cut , and that  could be the leak.and make sure the wire mesh is pushed in , not sticking out. it could put one fuzzy on the sealing surface and cause a leak there too.Maverick thinks im cleaning crazy, but a shiny clean sealing surface is crutial!

Title: Re: top dead center Post by Greg_650 on 01/12/07 at 08:56:47 franch wrote: Yeah, she was clean as a wistle. used permatex copper there too. my buddy helped me guide the head cover back in place while I manuevered the 2 bolts that stay with the head cover so that we didn't inadvertently smudge any sealant off. it definitely appears to be leaking in that area you show in your pic. I had spent lots of time scraping of old oil sludge and road grime from there with a dental tool before putting it back together. maybe, just maybe its old oil that got heated up and is spreading. never got a chance to hit the car wash. also noticed it's already pooling in there. having taken the head cover off once I am not too shy to do it again, wasn't that hard just time consuming. I'm going to move her back in next to the woodstove and do it all over again including that compression washer. One thing that I did last time...when I had the head off of another Savage... I took a good flat file to those copper washers.   You can recondition them nice and smooth and reuse them if you want.

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