SuzukiSavage.com - Thumpin' Special......On The Road Again!

Dave

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Re: Thumpin' Special......On The Road Again!
Reply #330 - 07/04/24 at 16:52:50

Well it has been more than 4 months since I last rode the Cafe' bike, and I am missing it. Sad

It was a rainy 4th of July here - no picnics planned and I could not do any yard work - so I decided to chase down that oil leak.

I began by taking off the bodywork - not too filthy under there for having 17,000 miles since the last time it was apart this far to do the paintwork.

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Someday I will be old......But not today!

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #331 - 07/04/24 at 16:57:29 I got a bit carried away, and before I knew it the thing was torn down to the crankcase! I figured while I had the thing apart I might was well get to the 94mm Wiseco flat top piston work! The rockers look good.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #332 - 07/04/24 at 16:59:13 The cam looks good! It is a Webcam Stage 3 from Lancer.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #333 - 07/04/24 at 17:00:42 The combustion chamber and valves look good. I had polished the valves and head to a shiny finish when I built this engine......you can't tell now that is is covered with carbon.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #334 - 07/04/24 at 17:01:19 The piston likewise had a bright shiny top when it was installed 12 years ago.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #335 - 07/04/24 at 17:02:27 There are a few small scrapes on the inlet side of the piston - it is amazing how deep the photo makes them look. They are actually very light. The top of the piston has some carbon on the top edge - this is the only place that occurs. It likely has something to do with the top ring gap being in that area.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #336 - 07/04/24 at 17:04:01 The exhaust side of the piston.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #337 - 07/04/24 at 17:04:39 The left side of the piston.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #338 - 07/04/24 at 17:05:35 The left side of the piston.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #339 - 07/04/24 at 17:07:23 The exhaust side of the cylinder bore. This is the side where the piston has some scratches. The scratches have no depth to them - more of a scuff.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #340 - 07/04/24 at 17:08:06 The exhaust side does not have any marks and is smooth.
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Dave

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Re: Thumpin' Special......On The Road Again!
Reply #341 - 07/04/24 at 17:15:26

I am not sure what to say about the leak - I could not really tell why it had suddenly began weeping oil out the hole that passes from the exhaust port to the opening back on the right side of the carb inlet. I had thought it might be the right rear cylinder head stud - but that was dry up at the nut and copper washer....and the stud was dry when I removed it.

The stock multi-ply head gasket had been weeping oil all through the layers, and the front center cylinder nut had a lot of oil on it when it was removed. I will check the head to see if it has an excessive amount of warping - and also check that center front head stud to see if it is pulling out. The leak did not appear to be up front - it was at the right rear and in the fins above the head gasket.....the Versy head plug appeared to be dry and clean underneath and I don;t believe that was the source of the leak.

Tomorrow I will begin cleaning things up and get ready to start installing the 94mm Flat Top piston. I have coated the top with Cerakote thermal barrier.....no idea if it has any real benefit but is supposed to help reduce the heat transfer to the piston.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17938 Camp Springs, Kentucky Gender:	Re: Thumpin' Special......On The Road Again! Reply #342 - 07/04/24 at 17:31:06 This is where I am at when I stopped for the day.
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badwolf Serious Thumper Offline Ridin' my Lil' Bagger - 153k miles so far Posts: 797 Palm Beach County, FL Gender:	Re: Thumpin' Special......On The Road Again! Reply #343 - 07/04/24 at 17:47:00 Dave, Check your old pistons oil holes front and back. See if they are starting to gunk up, or maybe you don`t have enough miles on it yet. Just wondering how soon that starts. (or maybe it was my seldom over 4k riding style)
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1360 Houston, Texas Gender:	Re: Thumpin' Special......On The Road Again! Reply #344 - 07/04/24 at 18:00:27 Impressive day’s work! WOW!
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