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Message started by 650LOVER on 03/17/11 at 12:47:30

Title: i need help please. engine shut down.
Post by 650LOVER on 03/17/11 at 12:47:30

i was going 75mph on I-95 in south of Florida, suddenly the engine stopped like when you r out of gas, but more noise. i pulled cluch & brake then pulled over the side of hiway. i check to see what s happened... maybe the starter jammed ? i disconnected positive cable from the starter then tryed to push start, but no sounds... there was lot of smoke came out from air box ( i nolonger use it caz i have corn mesh air filter, however, air box is still there & connected to breading housess) smoke was not black & no electric burn smell. my guss is that piston & head burned. i must conffes, a few months ago i made big stupid mistake when i was chainging oil that is i forgot put oil then ride bike for 2 miles without oil that could caused this problem ? since that my mistake i ride about 5,000miles. i just got towed my savage to home but i haven't got into yet. i dont know where to start. would anybody please give some suggestion & help. i apliciate your time. my savage is 2002, about 25,000miles. stage III. the shop is too expensive for me. i hate see my bike go into junk. sorry for my english is not good.

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 03/17/11 at 13:15:27

start here...
http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1191167029

... when's the wake?

Title: Re: i need help please. engine shut down.
Post by babyhog on 03/17/11 at 17:08:21

25,000 miles... oh I hate to read that. I wish you had checked in here a few thousand miles ago. Please let us know the outcome.

(And your English is fine. Where are you originally from? I assume you are non-American in Florida?)

Title: Re: i need help please. engine shut down.
Post by kimchris1 on 03/17/11 at 21:20:40

If you want to spend the time, their are people here
that can help. Lots of information in the tech section.
If you can't find the information you need there, ask
here and someone will gladly point you in the right
direction.
Another option would be to find another bike and use
your old one for parts. Just a suggestion.
I wish you all the best. hugs.. :) kim

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/18/11 at 14:04:19

6A796E6F707D7B79722D1C0 wrote:

start here...
http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1191167029

... when's the wake?

thank you for your rich infomation. i'm kind of discouraged by the task before me. at the same time i need to save money as much i can, i'm donating japan disaster relief through red cross & global giving. i hear they are not getting much of donation that compare to haiti & katorina.

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/18/11 at 14:07:03

2023222F2D374E0 wrote:

thank you for your reply. yes, you r correct, im originally from your suzuki savage came from.

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 03/18/11 at 14:16:21

677176662E67170 wrote:

I'm sure we all feel deep sympathy for our brothers across the sea.

Once you get that cover off, you'll most likely find the culprit.

Then we can assist you further.

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/18/11 at 14:16:42

70727678736972682A1B0 wrote:

thank you for your suggestion. i wish that i had garage where i can keep & leave everything then i can come back & continue what s left.

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/18/11 at 14:20:13

544750514E4345474C13220 wrote:

[quote author=677176662E67170 link=1300391250/0#4 date=1300482259]thank you for your rich infomation. i'm kind of discouraged by the task before me. at the same time i need to save money as much i can, i'm donating japan disaster relief through red cross & global giving. i hear they are not getting much of donation that compare to haiti & katorina.

I'm sure we all feel deep sympathy for our brothers across the sea.

Once you get that cover off, you'll most likely find the culprit.

Then we can assist you further.[/quote]
yes, im going in 2 c what s in there. i'll report my finding later. until then thank you so much. most likely i need few days

Title: Re: i need help please. engine shut down.
Post by kimchris1 on 03/18/11 at 17:43:59

Best wishes on finding out the problem.
Nothing worse than having a bike and
not being able to ride it..

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/18/11 at 18:25:40

544750514E4345474C13220 wrote:

I'm sure we all feel deep sympathy for our brothers across the sea.

Once you get that cover off, you'll most likely find the culprit.

Then we can assist you further.[/quote]
i openned the case. these are my finding;
1) plunger is out from housing about 20mm or 1.5"
2) many metal pieces, like some shaved off aluminum that the size of 1/4" piece which is the largest, several smaller pieces & some like grain of sand.
i'll try send photos.

that gasket alone cost that much $22 + shipping @bikebandit.
http://[/img][img]

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/18/11 at 18:37:34

i know this is my learning prosess of understanding more of my bike. i think that people like me can learn only by making mistakes. i wander how many more ? today was a nice day here in south florida, perfect day for bike ride. i couldnt ride but i started open the case & try se what in there. its not good. dont know what to do next...
2F2D29272C362D3775440 wrote:

Best wishes on finding out the problem.
Nothing worse than having a bike and
not being able to ride it..

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 03/18/11 at 18:52:02

796F68783079090 wrote:

1) plunger is out from housing about 20mm or 1.5"
2) many metal pieces, like some shaved off aluminum that the size of 1/4" piece which is the largest, several smaller pieces & some like grain of sand.

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/20/11 at 10:29:33

342730312E2325272C73420 wrote:

[quote author=796F68783079090 link=1300391250/0#10 date=1300497940]1) plunger is out from housing about 20mm or 1.5"
2) many metal pieces, like some shaved off aluminum that the size of 1/4" piece which is the largest, several smaller pieces & some like grain of sand.

Next step take the head cover off.
http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1099227295

I think you dropped a valve.

How to post pics (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1240899665)[/quote]
sorry my photos were too large for posting.i'll try again later.
if that valve is dropped, do you think i can still repair it ?
i'll open the head most likly tomo. i dont have a garage. i need to watch out the rain. & also, if i open them i need to put them back & close same day, caz many critters like gecco, lizzerd, spider... will make home inside. not mention that maintenance crews cut grassess then they use blower that will fly many gassess & sands up in the air into inside of bike. porgress is very slow but i'll get back with you for your teaching asap after i open the head. thank you my teacher.

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 03/20/11 at 10:57:24

You need to upload your pic's to someplace like bikepics, then link them here.

If it's a dropped valve, new piston, you need to bore the cylinder, have the head reworked, at least one valve.

Easier to get a used engine and swap it out...
http://cgi.ebay.com/ebaymotors/89-SUZUKI-LS650-SAVAGE-engine-_W0QQcmdZViewItemQQhashZitem2a0ee276cbQQitemZ180638349003QQptZMotorcyclesQ5fPartsQ5fAccessories

Or use the parts to rebuild yours.

If it were me, I'd take the engine out of the frame and take it indoors.
Lay down several layers of cardboard and plastic underneath.

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/24/11 at 16:42:07

352631302F2224262D72430 wrote:

hi, mr. buddha, this is my up date. i took tank off & 2 chrome top cover off. ive done this once before when i was changing spark plug. thenuinscrewed dozen bolts from head, i actually unscrewed 2 more by mistake. there are one on the top bolt with phillips head & one on the side for piston. however, im unable to lift the head cover( im not sure that the right name) i used wooden handle of a small ax against side of head cover from below then hammer it up ward many many time from many different spot. the cover is not moving or coming off at all. am i missing something here ? and also, i see more bad thing that is more metal shavings that size of 1/4" at the exaust port that indicates more significant damage to the engine i think. as you sugested that i like to take easier way, caz i need to complete this with my limited ability &resoure. however, i wander how do i know for sure that the used engine is good enough ?? the one for $300 on ebay was already sold.

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 03/24/11 at 17:40:44

http://suzukisavage.com/images/uploaded/HeadPattern01web.jpg

when you take off the chrome... L65 & C20 & 2xC25 (not included)

Take of valve inspection cover 4xL20

I count 14, all L's (except above L65 & L20)

Don't forget the one's under the covers. ;D

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/25/11 at 09:08:14

6E7D6A6B74797F7D7629180 wrote:

hi Vaslagen, i unscrewed about a dozen of bolts from top cover. then used a handle of small ax pushed against cover from bottom then hummered up many many times from defferent spot. however, the cover is not moving nor comming off. should i use some kind of wedge or something instead ? i have more bad news that is i can see more metal shavings size of 1/4 " at exaust port that indicates more damage to the engine. i'd like to take the easier way that you mentioned caz my limited resource & ability. $300 engine on ebay was already sold. how can i be so sure that the used engine is good enough. they sell them as it no gurantee or no return. i could be ended up with not only one but two unuseable engines with more money spent ????

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 03/25/11 at 11:38:21

Too bad $300 engine is a rare find.

You either eat a valve or burnt a piston for chunks to be coming out of the crankcase and valve port. You'll need to at least replace the piston. Maybe head work. Replacement engine or new bike is your best bet unless you really want to tackle it yourself. You'll need to split the case to get out all of the bits and pieces of the piston.

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 03/27/11 at 22:27:45

here's another possibility for you...

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1299372018

Title: Re: i need help please. engine shut down.
Post by 650LOVER on 03/31/11 at 12:25:27

2D3E2928373A3C3E356A5B0 wrote:

here's another possibility for you...

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1299372018

thank you sir. im realized that the engine on ebay was missed oppotunity.not only the price but that seller was 100% positive rate & only 2 hours drive away from my home. mean time, i'll keep my eyes on used engine & used bike. if i find used engine, what am i have to be awear of ? beside seller's positive rating ? and also, what was the main cause of this terreboro & maijer break down ? i'd like to prevent that to happen again. im sure that was my own foult.

Title: Re: i need help please. engine shut down.
Post by Serowbot on 03/31/11 at 12:29:56

564047571F56260 wrote:

and also, what was the main cause of this terreboro & maijer break down ? i'd like to prevent that to happen again. im sure that was my own foult.

Running without oil.... That killed it...

That's the one sure way to kill any engine...

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 03/31/11 at 13:53:21

2F393E2E662F5F0 wrote:

what was the main cause of this terrible & major break down ? i'd like to prevent that to happen again. im sure that was my own fault.

Have you torn it down yet and found the part that failed?
I'm still just guessing.

Title: Re: i need help please. engine shut down.
Post by topgunz1 on 04/27/11 at 12:54:04

I'm waiting to hear what his findings are since I'll be in a similar boat it seems. I picked up a project bike for cheap that was ran with no oil and seized, I'm not looking forward to what I'm going to find. Hopefully the bottom end survived and I can just replace the top and fix the cylinder with a bore job and a bigger piston. It will be a week or so before I can get into it, so I'm researching worst case scenarios until then.

Title: Re: i need help please. engine shut down.
Post by justin_o_guy2 on 04/27/11 at 14:19:44

I'm researching worst case scenarios

I could do so much with that,

Title: Re: i need help please. engine shut down.
Post by topgunz1 on 04/27/11 at 22:19:44

So far so good, pulled the clutch cover off and there were no apparent signs of major carnage. Cam chain tensioner is at 21mm but no metal pieces. Part of me expected the entire contents of the engine cases to pour out.

Title: Re: i need help please. engine shut down.
Post by verslagen1 on 04/27/11 at 22:51:33

6E756A7D6F74602B1A0 wrote:

Part of me expected the entire contents of the engine cases to pour out.

roflmao

21mm is pretty far, getrfixed.