SuzukiSavage.com - 1987 Savage Street Tracker build

TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #855 - 07/12/23 at 13:12:44 I had to carefully scrape the bits from the case seat for the cylinder, so none of it would get down into the crankcase.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #856 - 07/14/23 at 12:58:40 I needed to tidy up the workbench and get better organized for the motor assembly. Well, this chunk frees up some bench space! It's been quite some time since this was sitting in the frame.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #857 - 07/14/23 at 12:59:25 Other side
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #858 - 07/14/23 at 13:00:53 I hand tightened the side covers on it just to make it easier to wrestle in there. They will be coming back off to work on all the internals.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #859 - 07/15/23 at 13:23:53 I had to post this after I spent a good 30 minutes looking for my old cam chain tensioner, only to finally remember I shipped it to Versy as a core. Sheesh!!!
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #860 - 07/16/23 at 15:15:28 What twisted, demented Japanese engineer decided a 9mm thread was a good idea for the cylinder/head studs??!! I was going to replace my studs, but I can't for the life of me find 9mm nuts. The only ones I found were in a bulk of 50 for over $200. Maybe I won't replace the studs after all. Sheesh.
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DragBikeMike

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Re: 1987 Savage Street Tracker build
Reply #861 - 07/16/23 at 18:37:24

If you don't have the 9mm nuts, how do you intend to install your cylinder head?

The cylinder head is held down with four 9mm nuts (three acorn, one plain flanged). Use the one plain nut with one acorn nut to remove your studs (using the "jam" method). Install the plain flanged nut with the flange facing up. Then install an acorn nut. Jam the two nuts together and remove the stud. Repeat for the next three studs.

You're gonna have to remove at least the right-rear stud in order to get your cylinder and head installed. There isn't enough room between the stud and frame to get those components past the stud. Best to remove all four studs. As long as the studs are straight, I doubt you will need to replace them.

This old post might be helpful.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1609889036/0

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Re: 1987 Savage Street Tracker build
Reply #862 - 07/17/23 at 03:41:26

It is important to use the acorn nuts, as they seal oil from flowing out of the head.

The left front stud has oil flowing down around the stud to the lower crankcase, it is the drain for the head. At least one member has had an oil leak when this area was not sealed properly.

The top of the right rear stud is inside the cam/rocker area and in the oil spray area. About 2" down the stud passes through an area where it is exposed to the air flowing through the head from the passage alongside the exhaust port back the right side of the engine to the area alongside the intake port. One member had an oil leak in this area when he did not get the copper washer/nut sealed properly.

The left rear stud also has an acorn nut but is exposed to the air. at the top of the head....I am not sure why they used an acorn nut there and not on the right front where they used a plain nut.

Follow DragBikeMike's advice for installation of the nuts.....leaky head studs are a nuisance! I did my engine long before Mike did the analysis on torque values and I just applied a small amount of sealant on both sides of the washer and used anti-seize on the threads and it has been working fine - but Mike's method is far more precise and based on science!

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TheSneeze

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Re: 1987 Savage Street Tracker build
Reply #863 - 07/17/23 at 08:09:04

I have all the nuts. This motor has been apart for so long I didn't realize one of the four wasn't an acorn nut. I am overthinking things again, or just not paying attention. One of my studs has some corrosion on it which is why I decided to replace them. Thanks for the easy solution to my stud removal dilemma. 9mm hex nuts are not easy to find.

Any input on the bead of sealant on the base gasket? I wonder if the heat of the motor causes it to melt? Seeing it crumble like that causes me concern.

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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute

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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #864 - 07/17/23 at 08:43:22 Thanks for the link to the old thread on this head stud issue. I had obviously read it before, and responded at the time.
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TheSneeze

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Re: 1987 Savage Street Tracker build
Reply #865 - 08/23/23 at 14:28:25

This month has literally been a rollercoaster of emotions (and a lot of time away from my shop!). I spent 2-1/2 weeks in Canada, visiting one of my brothers. Went fly fishing (it was epic!), visited the Canadian Bomber Command museum, played in a poker tournament (came in 2nd, and in the money!), and finished off the trip with a bourbon tasting party in Portland, OR. Three days after returning, my mother passed away after a long battle with Alzheimer's. I had another brother visiting for a week due to the death in the family. The bustle has finally started to die down, and we have no plans of travelling for several months. Time for some much needed shop therapy to get my head straightened back out.

The cylinder head fastener mods are first on the list. I just received my #47 carbide drill bit for the cam today. I went to town to the local O'Reilly's Auto Parts store and picked up the Dorman exhaust studs. I have ordered some aluminum bar to make the cam fixture, but it won't be here for about a week. In the meantime, I am going to set up my cylinder on my mill and get the three head bolt threads drilled out. I will get the grade 8 fasteners on the next trip to town.

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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute

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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #866 - 08/23/23 at 14:30:05 So no one has an opinion on the base gasket sealant doing this when torqued?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28770 L.A. California Gender:	Re: 1987 Savage Street Tracker build Reply #867 - 08/23/23 at 16:55:29 if that's a preformed strip on the base gasket, then that's what I would expect, a dry strip that's crushed held in place by pressure, then upon release tearing up into strips.
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DragBikeMike

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Re: 1987 Savage Street Tracker build
Reply #868 - 08/23/23 at 18:27:32

I'm very sorry to hear about your Mom. That's a tough illness to deal with. Your Mom and your family must have gone through a lot.

Have you checked your quench clearance yet? As I recall, you did check it. If so, are you planning to change the quench clearance (increase or decrease)? If yes, then the OEM gasket won't be used. You will be using a copper gasket of the correct thickness to achieve .035" to .040" quench clearance.

I agree with Versy on the sealant bead. It looks like it is behaving as expected.

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Ruttly Serious Thumper Offline Thumpers Rule Posts: 4997 Manteca , CA Gender:	Re: 1987 Savage Street Tracker build Reply #869 - 08/23/23 at 21:45:33 Condolences
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