Day 1: (no pictures)Removed seat. Hey, this is easy.
Removed left side cover, disconnected negative battery terminal. No problem.
Attempt to remove fuel line from petcock. Hose takes some coaxing to be removed.
Attempt to remove vacuum line from carburetor. It wont move. Eventually, pliers fix the problem.
Disconnect speedo cable, don't loose the o-ring!
OK. Time to remove the gas tank. Instructions say to slide back.
Hrm, it won't move back. Oh, that's because the petcock is busy scraping the paint off the frame.
Twist slightly left, shimmy, and a wiggle. Got it!
OK, lets get this chrome off. No problem, right?
DARN hose won't let go. Finally, remember pliers solution. Yay!
Before we get to the headcover, lets remove the white spacer.
2 hours later - 1 screw has been removed from the top of the carburetor.
1 hour later and 1 trip to the store, the screws have been removed.
Removing the white spacer was the easy part.
Carburetor is back together.
Day 2: (pictures 1-35 here)The pictures are pretty random, in quality and content.
Timing inspection cover, dinged. Nickel, bent. Heavy duty scraper + bench grinder = world widest screwdriver and success.
Decomp cable, that was not fun. Until I read the instructions. Then it was easy.
Valve inspection covers, off!
Spark plug...NUTS. No spark plug tool in the Suzuki tool bag. That's OK, I'll just go buy a 17mm deep socket. Double NUTS. It's 18mm. That's OK, I'll just go buy a 18mm deep socket. *grumble grumble*
Now to find TDC. Hey, that's not so hard. Just keep spinning until it make sense. Did almost bind up a screwdriver in the spark plug hole. That was a bad idea.
OK, time to remove bolts. darn there's a lot of them. The ones a socket can reach, easy! Too bad my 10mm wrench is just rounding the rest of them off. That's OK, I'll just go buy a decent wrench. *grumble grumble*
Finally, cover is off!
And starting to get cleaned!
Questions:
* Other than rubbing gently with a lint free cloth and alcohol, any suggestions on getting the old sealant off?
* How do I get the head plug out?
* There's only 2 positioning dowels? (I hope.)
Day 3:Work and family.
Day 4: (pictures 36-39 here)Did a little more cleaning of the old sealant.
I'm beginning to worry about engine contamination. I've kept it covered, but it's been 4 days.
Figured out all the torques I need to set.
Figured out how to put a torque wrench on the end of a combination wrench to get the cylinder head-to-cylinder nuts on the fore and aft.
Torqued! That was anticlimactic.
Tape the two bolts into the head cover and practice putting it on.
Sealant!
Put the head cover on.
CRAP! I forgot to anti-seize L70. Oh well. I'm not pulling the head cover off unless I have to.
Put the rest of the bolts in and hand tighten them down.
Head cover bolts torqued!
To get to the bolt under the intake valve timing inspection cover use an offset box wrench at the end of your torque wrench. Only took me 2 hours to figure that one out.
Upper engine mount reinstalled.
Decomp back together and adjusted to 4mm.
Tomorrow, valve clearance.
Day 5:That was interesting.
Checking the valve clearance? Not so bad once you got the hang of it.
Torquing the lock nut without the adjuster moving? Not going to happen.
All the clearances were about 0.005", but I was curious if I could get them to 0.004". So I attempted to adjust one. Then I spent the next hour trying to get it back to 0.005". Using the torque wrench wasn't an option at all.
So I unadjusted one and left the rest as they were. Everything is bolted back up, I haven't started it yet to see if I adjust it properly. That's for tomorrow.
Day 6:Work and family.
Day 7:Engine sounds good.
Decomp makes a much louder clank than I remember.
Bolted everything backup. Will ride tomorrow.
Thanks to everyone for the help.
-D. Dwarf
Edited: 6/12 - Added day 7.