SuzukiSavage.com - Engine head and cylinder rebuild

Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2625 Amongst the Twisty Roads	Re: Engine head and cylinder rebuild Reply #15 - 04/04/18 at 08:55:22 DON'T FILE DOWN RINGS Are you trying to fit the rings onto the piston or the piston/rings assembly into the cylinder? Are they the correct rings for your piston? Have you measured the cylinder bore?
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justin_o_guy2

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Re: Engine head and cylinder rebuild
Reply #16 - 04/04/18 at 09:38:07

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?

What do you mean
Won't budge?
Did you check the ring/groove fit by simply putting the ring against the piston and rolling it around to prove that the groove would accept the ring all the way around?

Do you have a dial caliper?

Did you clean the ring grooves?

The old ring snapped off to get a factory square end to drag carefully around the groove is helpful.

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josesito

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Re: Engine head and cylinder rebuild
Reply #17 - 04/04/18 at 14:45:25

I bought OEM rings. Tried to fit the inside the cylinder and they have a really tight fit, almost scratching the cylinder. I cut myself trying to fit them inside and this is just with the cylinder removed from the motor and also the piston.

I was messing around seeing and comparing the old rings fit to the new rings fit. The old ones seem tight enough but maybe its just the place where the cylinder begins that has a smaller diameter then where the piston actually slides on.

I did roll them around the piston. I am lacking any motorcycle tools so messuring stuff is very limited. I just bought the stuff and wanted to bolt and play.

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justin_o_guy2

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Re: Engine head and cylinder rebuild
Reply #18 - 04/04/18 at 15:48:37

I wouldn't do that on my first go inside a motor.

You might be ahead to haul the jug, piston and rings to someone who can show you how to handle them,

The parts guy might just call a mechanic up to the counter to give you a quick
How To, fernuthin..

You were working from the bottom of the jug when you were working with the rings, right?

And no, they don't want to turn inside the cylinder.

I don't think I could get a ring in that isn't on the piston.

When I did a Raptor top end I put rings on the piston, oiled everything, ran the piston up the bore, check end gap.

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josesito YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Engine head and cylinder rebuild Reply #19 - 04/04/18 at 16:10:02 Yeah the jug was upside down and I was playing as the piston would go. I guess I have to keep doing my homework.
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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 #20 - 04/04/18 at 16:23:06 If the gap between the ends of the ring disappears when you put the piston in, that won't work. The manual states the required end gap.
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josesito YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Engine head and cylinder rebuild Reply #21 - 04/04/18 at 16:32:41 Yeah I just seen how to measure the end gap. Only ring into cylinder no piston involved.
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josesito

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Re: Engine head and cylinder rebuild
Reply #22 - 04/23/18 at 14:08:54

Hello Fellow Savages,

I re-built my head, but wanting to adjust the decompression starter i noticed I cant place the engine on TDC based on the mark on the 17mm stator/rotor indicator. I crank it forward looking for TDC but It will never hit the mark.

Did I time the engine wrong? I noticed when I go to start the engine black smoke comes out of the carburator/air flow hole. Is this normal?

Thanks for the input.
Regards.

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josesito YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Engine head and cylinder rebuild Reply #23 - 04/23/18 at 15:25:40 Could it be the chain slack/tension wont line up with the TDC marks on the rotor/stator case? Like the chain is tight and the TDC mark is somewhat off? I cranked it and it started nicely just stalled on idle, but the black puff smoke is what worries me here. It was just when starting tho then It stopped.
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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 #24 - 04/23/18 at 15:58:32 Howzit run?
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josesito YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Engine head and cylinder rebuild Reply #25 - 04/23/18 at 16:14:04 It runs nicely, just stalled in less than a minute due to lack of throttle adjustment/idle. I havent been able to make it run again though. Only decompression selenoid goes off and nothing happens. But it did run.
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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 #26 - 04/23/18 at 16:47:06 Check the battery
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josesito YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 24	Re: Engine head and cylinder rebuild Reply #27 - 04/24/18 at 08:56:39 Yeah a relay was off. Thanks for the patience and I know my spelling isn't great. Yesterday it ran good for a around 20 seconds but then it sounded out of time then I couldn't turn it on again just got a loud backfire. I think it is set out of time and I am going to have to time it again. Fail in order to learn.
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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 #28 - 04/24/18 at 09:05:26 You can prove the timing is right or wrong without tearing it down. Get the crankshaft on TDC compression and check your valves.
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josesito

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Re: Engine head and cylinder rebuild
Reply #29 - 04/24/18 at 11:24:47

Hello,

I did check the valve gap when on TDC. They both have little play and I assume the piston is on TDC, but the mark on rotor is wrong according to the manual. The mark is at 1 o'clock when it is supposed to be at 3 o clock next to the crankcase

Eventually I will take the valve cover off, clutch cover off and remove the tensor and time again.

Thanks,

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