SuzukiSavage.com - Engine head and cylinder rebuild

josesito

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Engine head and cylinder rebuild
03/20/18 at 14:23:07

Hello Savages,

I am in the process of rebuilding the motor and at this point in time i need to get the cylinder on, head and head cover.

Any important points i should know about?

The bike is getting new
-Piston rings
-Cylinder hone
-Cylinder gasket, head gasket
-Brand new tappets
-Valve seating re-done
-Brand new OEM valve seals

I know about checking the cam chain tensor and putting RTV on the plug.

Any other important stuff I should check out for? Tongue

It's my first time building an engine and I am doing it base the clymer manual.

Thanks alot the motor at this moment is without a cylinder.

Salut!

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josesito

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Re: Engine head and cylinder rebuild
Reply #1 - 03/20/18 at 14:30:58

The valve seating I am worried about, It was done at a machine shop and I am coming from a bad head leak and Im fearfull the valve seating may have done considerable damage in order to still spill oil into the cylinder.
I am worried maybe a machine ate much of the steel out the seats and the valves wont seat correctly, or am I just paranoid.

Regards.

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2625 Amongst the Twisty Roads	Re: Engine head and cylinder rebuild Reply #2 - 03/20/18 at 15:39:23 As long as the machinist had the valves on hand and had the opportunity to lap the valves after installing the new seats, you're probably good to go.
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justin_o_guy2

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Re: Engine head and cylinder rebuild
Reply #3 - 03/20/18 at 15:57:53

Don't forget to hang the bolt in the head cover that you can't put in once the head cover is on. And I can't remember what to do with the upside down one in the corner.
I hope you kept the bolts in a piece of cardboard with the hole they belong in. And their oil seal washers.

Use the right sealer on the head cover.
And use assembly lube on the cam and protect your lobes from a dry pounding.
The head cover bolts and threads in the head are easy to wreck.
Use a 1/4" ratchet, thumb on the head, feeeel of the bolt as it starts to clamp.
Run the torque pattern four or five times, getting it clamped down evenly, slowly, carefully.
And remember
It's easier to fix a drip than a busted or stripped part.

Three Bond or equivalent, applied thin and even.
The head has places where you Can put sealer, but the head Cover doesn't have a corresponding surface, so pay attention there.

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GT61 TURBO ZX14

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Re: Engine head and cylinder rebuild
Reply #4 - 03/21/18 at 14:17:22

Ya get a 94mm piston from Lance it'll make the motor run better and more efficiently if you can afford it if not when you rebuild it just check the cranking compression to make sure it's good and then after you run it for a while brake and should be done in about a half an hour to an hour then check it again if it's still low then you need to bore the block or the head ain't seating

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Engine head and cylinder rebuild Reply #5 - 03/21/18 at 17:50:20 It's a good time for a hotter cam.
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Dave YaBB Moderator ModSquad Online SuzukiSavage.com Rocks! Posts: 17802 Camp Springs, Kentucky Gender:	Re: Engine head and cylinder rebuild Reply #6 - 03/22/18 at 04:50:17 justin_o_guy2 wrote on 03/21/18 at 17:50:20: It's a good time for a hotter cam. A hotter cam.....and a Wiseco! You won't regret it.
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josesito YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Engine head and cylinder rebuild Reply #7 - 03/22/18 at 16:04:30 Yeah i dont think i can spare out 200 usd for a piston at the moment, besides its my first bike i just want to ride it. Maybe in the future i can make some kind of mod to it. I really want to ride this thing
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Matchless G11

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Re: Engine head and cylinder rebuild
Reply #8 - 03/22/18 at 16:42:29

josesito wrote on 03/22/18 at 16:04:30:

Yeah i dont think i can spare out 200 usd for a piston at the moment, besides its my first bike i just want to ride it. Maybe in the future i can make some kind of mod to it.

I really want to ride this thing Cool

Ride?
And not know the enjoyment of wrenching?
You have a Suzuki you ride 90% wrench 10%
Buy my old bsa then it will be 90% wrenching 10% riding. (if you are lucky) Grin

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josesito YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Engine head and cylinder rebuild Reply #9 - 03/26/18 at 14:59:38 I do want to work on it, its just I have bearly ridden this thing since it was lacking major adjustments. What is bsa? is it something i want?
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Dave YaBB Moderator ModSquad Online SuzukiSavage.com Rocks! Posts: 17802 Camp Springs, Kentucky Gender:	Re: Engine head and cylinder rebuild Reply #10 - 03/26/18 at 18:06:44 josesito wrote on 03/26/18 at 14:59:38: What is bsa? is it something i want? Kids.....aren't they cute!
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Engine head and cylinder rebuild Reply #11 - 03/26/18 at 22:36:08 Art Linkletter would have looked at the kid, then the camera And laughed... Just precious..
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LANCER

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Re: Engine head and cylinder rebuild
Reply #12 - 03/27/18 at 02:55:34

BSA .... Bermingham Small Arms. Once the largest motorcycle manufacturer in the world, until the late 50's & early 60's when they did not keep up with technology and the Japanese blew them out of the water.
"You meet the nicest people on a Honda"

BSA's most well known machine was the BSA GOLDSTAR DBD 500.
It ruled the 1/2 & 1 mile flat tracks for many many years.

I loved that bike.

It was because of that bike that I first got a Savage.

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josesito YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Engine head and cylinder rebuild Reply #13 - 04/04/18 at 08:21:22 COOL info there. Thanks! Anyone know if the rings should have a real tight fit? I am trying to fit new rings, but they wont budge. I will be carful as i have cut myself already but should i file them down?
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Dave

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Re: Engine head and cylinder rebuild
Reply #14 - 04/04/18 at 08:53:20

josesito wrote on 04/04/18 at 08:21:22:

COOL info there. Thanks!

Anyone know if the rings should have a real tight fit?

I am trying to fit new rings, but they wont budge.

I will be carful as i have cut myself already but should i file them down?

If you are installing OEM Suzuki rings.......they should not have any problem fitting into the bore. They don't come oversize....unless you ordered rings for a larger bore (oversized).

Do you have a manual? It will list the end gap acceptable range.

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