SuzukiSavage.com - Cylinder remove

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Cylinder remove
10/04/08 at 18:00:33

I remove the cylinder head without removing the engine. I now discovered that one of the exhaust valve broke and it stick into the head of the piston. So, I need to replace the piston as well as the exhaust valve.

I would like to know if there is any possibility to remove the cylinder without pulling the engine out of the frame?

I can't find my camera, otherwise I can post picture for you to look at. Very interesting.

Any info is appreciated.

Thanks,
Seattle_Savage

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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: Cylinder remove Reply #1 - 10/04/08 at 18:01:47 You can do it, but you'll have a much easier time if you just pull it.
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Seattle_Savage YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 37	Re: Cylinder remove Reply #2 - 10/04/08 at 18:08:26 Thank you! with your experience. How long does it takes to get the engine out of the frame? i took most of the thing off, but if I need to take the engine out, I now need to mess around with the left side of the engine which taking the belt out etc...
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Trippah Serious Thumper Offline I ride, therefore I am. Posts: 2517 central Mass Gender:	Re: Cylinder remove Reply #3 - 10/04/08 at 18:49:33 Even though its possible to take the head off without removing the motor(in some cases), there is precious little room for a torque wrench for reassembly.
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Seattle_Savage

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Re: Cylinder remove
Reply #4 - 10/05/08 at 08:36:24

This will be my project for the next few months once I have time.

Some how, one of the exhaust valve broke at the base and during the firing, it turned around and stick it into the piston head. I look at the cylinder, there was no damage, but the piston needs to be replaced and I will replace the new ring set as well.

http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19261.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19271.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19281.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19291.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19301.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19311.jpg

Any idea what happens in this case?

Seattle_Savage.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Cylinder remove Reply #5 - 10/05/08 at 08:47:47 This is the 2nd dropped valve in a coouple of months..whats going on?
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Seattle_Savage YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 37	Re: Cylinder remove Reply #6 - 10/05/08 at 09:01:41 Hah... I feel a bit better now to know that mine is not the only case. Seattle_Savage.
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Yonuh Adisi FSO

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Re: Cylinder remove
Reply #7 - 10/05/08 at 11:28:24

Seattle_Savage wrote on 10/04/08 at 18:08:26:

Thank you! with your experience. How long does it takes to get the engine out of the frame? i took most of the thing off, but if I need to take the engine out, I now need to mess around with the left side of the engine which taking the belt out etc...

I can have the engine out of the frame in about half an hour, but the first time I did it took me about two to three hours. Go slow and keep the Clymers/Service manual open in front of you the entire time no matter how good of a mechanic you are.

Once you do get the engine out, definitely inspect the case for that peace of broken piston.

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Check out Flight of Destiny http://www.amazon.com/dp/B00H9130XC

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saluteTOme Full Member Offline Posts: 189 Newark, DE Gender:	Re: Cylinder remove Reply #8 - 10/05/08 at 16:20:19 wow, thats interesting the say the least.
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88pagan

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Re: Cylinder remove
Reply #9 - 10/05/08 at 16:47:33

Hmmm what's really going on here. I'm just waiting on the last couple parts to arrive this week and I'll be finishing my rebuild. This same thing happened to me. It's been months now and many $$ and now I'm getting a little apprehensive..If this happens to me again I don't know what I'll do. Guess I might need to follow the advice of some wise members here, might be ordering some new valves and seats just in case. I REALLY wanna get back to riding!! Good luck with your rebuild man. I've rec'd a lot of advise from the members here and so far everything is going well, if you need anything just holler

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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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Seattle_Savage

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Re: Cylinder remove
Reply #10 - 10/05/08 at 16:53:33

I have sometime today. So, I just took the engine of the bike and dis-assembly the cylinder and took the piston out. I was not too bad, it took me about 2 hours to do so since I do not have the service manual with me and I do not have all the tools that I need.

http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19321.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19331.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19341.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19351.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19361.jpg
http://i269.photobucket.com/albums/jj66/Crystal_RX/IMG_19371.jpg

Next step will be my trip to the dealer sometime next week to get the new piston & valves.

I check the ring sets and they are still good. Do I need to replace them as well?

Seattle_Savage.

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88pagan

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Re: Cylinder remove
Reply #11 - 10/05/08 at 17:07:15

Hmmm looks awful similar to my bike right now haha. I ordered all my parts from bikebandit.com. They're quick and reasonable. You can find your own stuff off their schematics without dealing with the stealer. Also, they're customer service was pretty good to me. I've places a few orders in the last few weeks cause I keep realizing I need more parts and when I talked to them fri the guy offerred to refund my shipping on the most recent order. Pretty cool

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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: Cylinder remove Reply #12 - 10/05/08 at 17:07:37 Seattle_Savage wrote on 10/05/08 at 16:53:33: I check the ring sets and they are still good. Do I need to replace them as well? Seattle_Savage. Any time you replace the piston, you MUST replace the rings, and do not forget to re-hone the cylinder.
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88pagan Full Member Offline God is just an imaginary friend for adults.. Posts: 237 Norco, California Gender:	Re: Cylinder remove Reply #13 - 10/05/08 at 17:13:11 Seattle_Savage..my post starts in the rubber side down forum as "anyone have any good news for me"..don't know if you'll find any good info there but worth a look. I'll try to post some pix early this week on my progress.
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Seattle_Savage YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 37	Re: Cylinder remove Reply #14 - 10/05/08 at 17:16:03 Thanks. i will use that post and continue with it then. Sorry for the stupid question. How do you re-hone the cylinder? Seattle_Savage.
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