SuzukiSavage.com - Anyone have any good news for me??

88pagan Full Member Offline God is just an imaginary friend for adults.. Posts: 237 Norco, California Gender:	Re: Anyone have any good news for me?? Reply #15 - 07/30/08 at 21:11:15 When I start removing the camshaft sprocket bolts do I really need to be at TDC? The manual says so but it doesn't seem like it would matter as I'm pulling the whole thing apart..or am I going to mess everything up if it isn't at TDC when I pull it apart??
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Anyone have any good news for me?? Reply #16 - 07/30/08 at 22:11:23 TDC will lesson the pressure on the bolts when you take them off. otherwise no, just set it to TDC before you put the cam back on.
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88pagan

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Re: Anyone have any good news for me??
Reply #17 - 07/31/08 at 10:24:32

Got it apart last night. Valve is obviously shot. The area by the valve in the valve cover? is chewed up a little..piston is shot..but the walls look just fine. Hopefully there isn't any other damage. So, is Clymers right and a professional should do the valve replacement or is this something you guys have done yourself?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Anyone have any good news for me?? Reply #18 - 07/31/08 at 11:25:42 Personally, I'd have a pro rebuild the head. Or pick up a used one.
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88pagan Full Member Offline God is just an imaginary friend for adults.. Posts: 237 Norco, California Gender:	Re: Anyone have any good news for me?? Reply #19 - 07/31/08 at 11:47:37 That's what I was thinking. Probably gonna be better to just pick one up seeing as several of the parts are going to have to be replaced anyways. Can I replace the piston myself though or am I going to have to take the whole engine to someone?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Anyone have any good news for me?? Reply #20 - 07/31/08 at 11:50:44 That you can do yourself. And I'd take the cylinder out and get it treated. I think it was savage greg who got it carbided or something.
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88pagan

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Re: Anyone have any good news for me??
Reply #21 - 07/31/08 at 18:51:44

Here we have it. Sorry the pix are crappy, I just took them with my phone really quick. Looks like it's going to be a new piston and valve...gonna replace the cam chain too I guess since I'm this far in. Anyone think that cylinder head is going to fly with those little chunks chewed up? Guess I could see what the shop says about it when I get a price on replacing the valve but that cylinder head is ExPeNsIvE! Actually I'd better take a closer look cause it appears it might be chewed up right where the valves seat Undecided

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96 Bobber - Screamin Eagle, header wrap, K+N cone filter, jetted, straight bar w/1.5" risers, solo seat, Ed. L fwd ctrls, custom rear fender, TKat, Metallic charcoal and polished all over.

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Yonuh Adisi FSO Serious Thumper Offline Savage Jedi (Knight) Posts: 3622 Pilot Valley NV, aka Tatooine Gender:	Re: Anyone have any good news for me?? Reply #22 - 07/31/08 at 19:17:51 Definitely check the bottom end for pieces of piston. Unfortunately the piston is aluminum alloy so a magnet won't work to fish them out.
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justin_o_guy2

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What happened?

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Re: Anyone have any good news for me??
Reply #23 - 07/31/08 at 21:15:24

What causes such death & destruction? Dang, what a mess. That head is done, IMO, a used one wouldnt be thatmuch $$, surely.
How fast were you running when it started making the big noises? If the cylinder walls arent messed up, Id say you got lucky. Looks like a lot of hard stuff was bouncing around in there a while.. You deffinitely have to pull that engine & open the sides & rock it around till you find all the little pieces of piston down in there.

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88pagan

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Re: Anyone have any good news for me??
Reply #24 - 08/01/08 at 06:18:36

Who knows? I'm hoping someone has some knowledge on what may have caused it so I can avoid it once I finish the rebuild..but, if it's just part failure I guess I got unlucky. Was only traveling about 35-40 when it happened. It was a slight pop, the sound of something bouncing around inside and almost immediately lost compression. I pulled the clutch and got off to the side of the road. I was heading uphill on a narrow 2 lane bridge. Once I finally got it pushed up the hill without getting run over I proceeded into the 7 mile walk home. Guess it could have been worse though

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96 Bobber - Screamin Eagle, header wrap, K+N cone filter, jetted, straight bar w/1.5" risers, solo seat, Ed. L fwd ctrls, custom rear fender, TKat, Metallic charcoal and polished all over.

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T Mack 1 - FSO

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Re: Anyone have any good news for me??
Reply #25 - 08/01/08 at 10:04:06

What caused it...... one posibility is valve adjustment.

For reference, here on the east side of PA, I got a full used head assembly, cam & all, for $200.

The first oversized piston kit (+0.5 mm .... or was it +0.05 Huh

) runs around $100 +/- some. Take note: the Suzuki OS Piston kit does not include a wrist pin, that's around $12 to $14 extra.

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Engineers design things, Technicians make them work.
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30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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ed daugherty

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Re: Anyone have any good news for me??
Reply #26 - 08/01/08 at 20:00:00

you will definitely want that boy bored out! looks can be deceiving. I would take the head and cylinder to a shop and have a mechanic look at it. you may get lucky and just need it to be honed. good luck. has anyone ever had one ported and polished? we used to do that with dirt bikes...i would love to hear from someone who has done it!

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88pagan Full Member Offline God is just an imaginary friend for adults.. Posts: 237 Norco, California Gender:	Re: Anyone have any good news for me?? Reply #27 - 08/02/08 at 14:51:06 Well I plan on taking it to a machine shop to get it rehoned but starting to think I might want to bore it out bigger and upsize the piston. Anyone do this? port and polish sounds good too. Now just need to find a darn head + cover...
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88pagan

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Re: Anyone have any good news for me??
Reply #28 - 08/09/08 at 08:56:26

Alright so I've been looking and looking. Still nothing, but, does anyone know what year Savage parts are interchangeable?..and if the s40 parts are also the same? Just wondering in case I come across something other than a 96 Savage. Also, by searching the schematics on Bikebandit I'm finding all the cylinder head assemblies throughout the years look just about the same. Thanks.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Anyone have any good news for me?? Reply #29 - 08/09/08 at 16:17:42 The guts are the same, trannys changed, but all the cams, pistons, cranks & rods & such are the same. Used parts are out there. There are even whole engines, as opposed to engines with holes.
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