SuzukiSavage.com - 2003 Savage ticking? Please advise

ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #30 - 09/14/14 at 09:36:37 are the underside of the rocker arms suppose to be worn light this?
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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #31 - 09/14/14 at 09:37:59 do you guys have this clump of metal screen in the engine vacuum port?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: 2003 Savage ticking? Please advise Reply #32 - 09/14/14 at 09:43:41 ghkizer1 wrote on 09/14/14 at 09:37:59: do you guys have this clump of metal screen in the engine vacuum port? Yes, and that's the breather port.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: 2003 Savage ticking? Please advise Reply #33 - 09/14/14 at 09:43:58 ghkizer1 wrote on 09/14/14 at 09:36:37: are the underside of the rocker arms suppose to be worn light this? no
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: 2003 Savage ticking? Please advise Reply #34 - 09/14/14 at 09:46:05 ghkizer1 wrote on 09/14/14 at 09:33:30: you can see the scratches on the top of the cover We call'm journals and them's bad.
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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #35 - 09/14/14 at 09:46:43 Dang, Verslagen, whats my best course of action here? What if I upgraded and modded this engine with new parts. Do they make a kit for that sort of thing? I'd like to save the engine if possible.
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Ed L. Serious Thumper Alliance Member Offline "We All go a Little Crazy Sometimes" Norman Bates Posts: 2808 Sunny Florida Gender:	Re: 2003 Savage ticking? Please advise Reply #36 - 09/14/14 at 10:12:46 Do a search in the Tech section for Oldfeller's "Simplified Refit of the Cam Journals". It shows how to repair a wiped cam journal in the head. As far as I know there isn't a retrofit kit for this, you will need to replace the head, cover, cam and rockers unless you can find a used assembly. Luck with it.
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NickGann Junior Member Offline SuzukiSavage.com Rocks! Posts: 75	Re: 2003 Savage ticking? Please advise Reply #37 - 09/14/14 at 16:53:56 That is some rough action there man. What would cause all this wearing?
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ghkizer1

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Re: 2003 Savage ticking? Please advise
Reply #38 - 09/14/14 at 17:02:08

I have no idea? Never opened up an engine before, I try to take care of mine so this doesnt happen. I got this bike for free and dont know the history of it.

If I venture an inexperienced guess I would say someone ran this bike dry. The top end either over heated or didnt get enough oil. Im on a mission to get this beast running.

Do you think i could get the head cleaned up at a machine shop, put in a new cam shaft and rockers and try this again? Or do I need a completely new top end?

Cheers!

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28661 Tucson Az Gender:	Re: 2003 Savage ticking? Please advise Reply #39 - 09/14/14 at 17:46:28 NickGann wrote on 09/14/14 at 16:53:56: That is some rough action there man. What would cause all this wearing? Low idle speed...
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Ed L.

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Re: 2003 Savage ticking? Please advise
Reply #40 - 09/14/14 at 17:52:09

Don't know if a machine shop would do the repair. The journals would need to be recut and the only way to get the meat for that cut would be to remove metal from the cover and head. Once you add up the machine work and new parts like a cam, rockers and gaskets you might be better off with getting a used motor. There is a good chance some metal from the rockers got into the rest of the engine so it would need a good cleaning.
The engine was probably run with a low oil level or too low an idle. An idle of 500 rpms sounds good but it needs to be around 1000 rpm to get the oil to the top end.

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ghkizer1

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Re: 2003 Savage ticking? Please advise
Reply #41 - 08/31/16 at 14:59:51

OK so I hate to revive a very old thread but maybe others are dealing with a similar problem. It has been almost 2 years since I got this bike and I'm just now getting around to working on it again so here I am. It was very discouraging to open up the engine and find the rockers badly worn, journals destroyed and camshaft damage. Someone must have run it with no oil...

Anyway, I have now bought a parts bike, took the head off and found a camshaft in good condition along with the rockers and head cover.

Question is, what would you guys do in this case? Would you try to swap the camshaft, rockers, and head cover out and run it like that or go further and replace the entire top end of the engine, or would you swap in a completely different engine? Also, I couldn't find a good walk through on removing the camshaft, do you have to get a special tool and remove the clutch or?

Any advise is greatly appreciated. Thanks in advance!!

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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #42 - 08/31/16 at 15:00:31 Here's a picture of how badly the old rockers were worn.
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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #43 - 08/31/16 at 15:20:41 this is what I'm trying to turn into something.
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ghkizer1 YaBB Newbies Offline Go COCKS! Posts: 36 Charleston, SC Gender:	Re: 2003 Savage ticking? Please advise Reply #44 - 08/31/16 at 15:23:07 camshaft looks worn at least on one lobe but maybe I could just file down the rouge edges and slap on the new rockers/head cover? replacing the camshaft is going to be a major job I'm guessing.
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