Hey guys, pleased to say my neighbor (we'll call him Dustin to protect honor) scored a free torn apart 1986 Savage from someone who was going to toss it. 33,000km, and everything organizingly dismantled.



However after 8 years of this bike sitting neatly in boxes, it ended up in the back of Dustins truck and later on his driveway where it collected sawdust from his garage. Long story short we were going to part it out but I decided to give it a go and see what I can do for my very first engine job.



Im only at the engine right now.

First thing I did was a mockup assembly, guessing where parts go, just to see if I might be missing something major. Seems to be all there.



I took it apart and cleaned out most of the sawdust and other junk. Bought some Ultra Black just to get a decent oil seal while I dump some oil in it, set the valves, and check for compression.



I basically finished it up, with a few leftover parts



Now I better ask some questions...


1) I used regular gasket paper + Ultra Black for the head gasket, was told it wont hold up, but for research purposes Im going to try it.

2) How can I crank the started directly off a batter/charger? Dont feel like mounting it into the bike or hand cranking with a socket anymore.

3) when setting the timing chain, I marked the white line on the flywheel at the 3 o'clock position through the cap checker thing for TDC. Then I lined up the cam markings with the block, lobes facing down, and mounted the chain, secured everything, dabs of grease and oil everywhere. Attempted to set the valves, everything seems to be functioning smoothly. Did I do this properly?

4) Can anyone Identify these extra parts

I havent been thru every nook & crannie on the bike, buy Im not really thinking the spacer & O ring are part of the bike. Yea, that sre looks like the clutch throwout pin,,& the bolts,, well, Id be looking up top of the engine for the long one, short one?? No clue.

Congrats on getting this far.

you did very well considering all you had was a box of parts to start with.
as far as the cam chain, how about a safety wire to keep it from falling out, at least just for demo purposes.

having a bit of problems with the clutch now that the pins in.

I pull up on the clutch lever on the clutchcase when its on and it wont budge. any ideas? should I be tightening the 4 springbolts all the way in?


http://i291.photobucket.com/albums/ll291/thetoolswingguy/Cruisers_GZLSTUVSVXV...

I also only seem to have only 10, or 11. not both???

alright, im leaving the clutch out until further notice.

Just mounted the engine, connected all the wires, and put a batter charger on the positive battery wire + grounded. all the lights come on and everything works, until you put the right hand engine switch to "Run", then I get a constant, loud, arch between the plug and the block.



I wanna tinker, but it sounds PAINFUl

One side of the coil is hot, the other goes to ground thru the CDI.

So you got a short on that wire.

The savage is really voltage sensitive.
A low battery will make it miss and pop.

you're right, 10 was hiding there. so here's the problem. Its all assembled, but the clutch thing still wont budge. ill snap some quick pics