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12 y/o LS650 ridden in winter (Read 360 times)
philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #15 - 05/18/19 at 14:51:54
 
The salt has also caused some bolts to freeze up. Snapped the head off one of the drive pulley cover bolts and today while installing a new AGM battery one the two cheesemetal screws in the battery box lock plate stripped out and had to be drilled.
I need to get my torque wrench and go through all the bolts and screws. Take each out as carefully as possible and apply antisieze and putting them back in at the correct torque specs.
Yay!
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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justin_o_guy2
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Re: 12 y/o LS650 ridden in winter
Reply #16 - 05/18/19 at 19:21:52
 
Acetone and A.T.F., mixed 50/50 for penetrating oil.
Hit the bolts you're gonna mess with every day for a few days.
An impact will break them out more safely than a wrench.
If you don't have a 1/4" rechargeable, or a compressor and an impact, you can get a handheld that you slap with a hammer.
If you get one of those, test it on a hard surface, no hammer.if it doesn't feel smooth, disassemble and smooth up the ramps.
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #17 - 05/19/19 at 06:15:54
 
justin_o_guy2 wrote on 05/18/19 at 19:21:52:
Acetone and A.T.F., mixed 50/50 for penetrating oil.
Hit the bolts you're gonna mess with every day for a few days.
An impact will break them out more safely than a wrench.
If you don't have a 1/4" rechargeable, or a compressor and an impact, you can get a handheld that you slap with a hammer.
If you get one of those, test it on a hard surface, no hammer.if it doesn't feel smooth, disassemble and smooth up the ramps.


Last night I was looking at torque limiting impact wrenches at Home Depot. Are they worth the extra money?
Also got a set of extraction bits. I managed to wreck the head of the rear seat screw  Sad
I’m gonna hit all the bolts with penetrating oil and go for a long high RPM ride and let vibration work for me  Cool
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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justin_o_guy2
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Re: 12 y/o LS650 ridden in winter
Reply #18 - 05/19/19 at 20:08:03
 
One dose of oil won't be enough.
Take your time.
Oil it every day for several days.
It's a lot easier than fixing busted stuff.

The trigger limits torque.

Run it on bolts the same size as the bike has. Waste a few dollars.
See what it feels like.
Beats drilling out busted stuff.
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #19 - 05/23/19 at 18:42:31
 
Time for the big guns. How do you like me now rusty nuts?
Cheesy
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F6B8BAEB-95D4-476B-8E65-519B9687A963.jpeg

07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #20 - 05/31/19 at 12:15:22
 
Can anyone recommend those purdy polished bolt kits seen on Ebay?
Like this one?
https://www.ebay.com/i/372086586751?chn=ps&mkevt=1&mkrid=711-117182-37290-0&m...
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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justin_o_guy2
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Re: 12 y/o LS650 ridden in winter
Reply #21 - 05/31/19 at 15:24:58
 
Got the old ones out?
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #22 - 05/31/19 at 16:16:36
 
Not the ones I’ve destroyed!  Grin

In all seriousness I’m contemplating stripping the bike down to the frame and sending all for powder coating at this point. The more I look the uglier it gets.

I’m putting together a shopping list now. I’m sure in the end it’s probably better to buy a brand new LS650 and swap my really nice engine into that.
I’m looking at buying used parts to replace all corroded beyond belief stuff and sending those out for stripping and coating in one big batch. Once it’s all ready I strip the bike down and send the frame for the refurbishment and then build it back up with all the good parts.
Toss the the remaining crap in the trash.
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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justin_o_guy2
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Re: 12 y/o LS650 ridden in winter
Reply #23 - 05/31/19 at 16:59:48
 
Go buy a new one
Pull the engine
Stick your ugly , running engine in it
Ride that while you tinker with the new engine
Swap engines
Reassemble the ugly one, sell it
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #24 - 05/31/19 at 20:54:42
 
While what you say makes perfect sense in many way JOG2 I kinda just put myself on another path.

Went ahead and ordered some crap. Something resembling a plan fell into place.
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #25 - 06/04/19 at 15:54:21
 
Got the estimate for prepping and powder coating the new crankcase covers - $75 for both. Need to pick a color now!  Cool
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #26 - 06/07/19 at 11:05:29
 
I’m prepping the crankcase covers for powder coating now.
With the clutch cover I need to remove the clutch actuator and arm.
Is the cotter pin the only thing holding it to the case?
Does the the clutch rod lever just slide off the shaft?
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #27 - 06/07/19 at 15:45:50
 
Nevermind above questions. Figured it out.
Look how clean and nice!
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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philthymike
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Re: 12 y/o LS650 ridden in winter
Reply #28 - 06/07/19 at 15:46:31
 
My new best friend!
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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE
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Re: 12 y/o LS650 ridden in winter
Reply #29 - 06/08/19 at 12:39:15
 
I would imagine you will need to remove the oil window prior to powder coating - if the sandblasting doesn't destroy it I bet the 400 degree heat in the oven will.

If you damage it pushing it out.....you can buy a new one from Suzuki.

LENS, OIL LEVEL 11971-33210  

$15.85
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