SuzukiSavage.com - Engine rebuild must do’s

REMTB

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Engine rebuild must do’s
01/21/22 at 19:25:12

am pulling the engine out of my 1987 project to fix some frame damage.

This is my first bike although I’ve been working on cars since I was a little kid and have an understanding of combustion engines, I’m planning to dive right in head first and give the old engine a bit of a clean up. I plan on replacing all seals and gaskets and rings. Bike rides fine, a little struggle going up hills with my 93kgs on it and feels like maybe a slipping clutch so will check that out.

Is there anything else I should be replacing or checking while I’m in there?

Any help will be much appreciated.

Also links to online OEM gasket/seal kits as the Suzuki dealers I’ve found near me have given up on the older bikes and have told me the newer s40 gaskets won’t all fit.

Cheers lads

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2625 Amongst the Twisty Roads	Re: Engine rebuild must do’s Reply #1 - 01/21/22 at 19:54:05 Cam chain, CCT and guide. I would look at the main bearing and if you see any signs of copper they should be replaced.
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REMTB YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 8 Auckland, New Zealand Gender:	Re: Engine rebuild must do’s Reply #2 - 01/21/22 at 20:14:19 Gary_in_NJ wrote on 01/21/22 at 19:54:05: Cam chain, CCT and guide. I would look at the main bearing and if you see any signs of copper they should be replaced. Roger that, cheers gary
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SoC

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Re: Engine rebuild must do’s
Reply #3 - 01/21/22 at 21:39:05

REMTB, that is a pretty bad ass build you have found. if it all works out you will certainly be profiling on it. Good luck and remember the thing about these bikes is too ride them and figure it out as you do that. Don't intellectualize it and try to fix what yet ain't broke. If it starts and rides, that's what it is about.

You have some issues with the exhaust, not that it can't be overcome, but any thread you follow will point out not to do a custom like this ride has. You will be chasing problems that no solution here has yet figured out. These bikes like some back pressure and baffles.

Good luck going forward and certainly keep us posted.

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REMTB

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Re: Engine rebuild must do’s
Reply #4 - 01/21/22 at 22:28:53

SoC wrote on 01/21/22 at 21:39:05:

REMTB, that is a pretty bad ass build you have found. if it all works out you will certainly be profiling on it. Good luck and remember the thing about these bikes is too ride them and figure it out as you do that. Don't intellectualize it and try to fix what yet ain't broke. If it starts and rides, that's what it is about.

You have some issues with the exhaust, not that it can't be overcome, but any thread you follow will point out not to do a custom like this ride has. You will be chasing problems that no solution here has yet figured out. These bikes like some back pressure and baffles.

Good luck going forward and certainly keep us posted.

Thanks for the info SoC, would love to just ride and enjoy it but unfortunately its not exactly road legal here in New Zealand, not thats it really stopped me yet but getting it out of the impound doesn't sound like too much fun.

Lucky for me the stock exhaust is in the box of spares the bike came with and after reading through a few threads i've started looking for a dyna muffler.

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justin_o_guy2

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Re: Engine rebuild must do’s
Reply #5 - 01/22/22 at 16:03:18

Don't guess
Know
The oil pump gear will go in backwards.

Mark it before you pull it.

Pulling side covers and head cover

Cardboard with the outline of the bolts, a slice, and each bolt goes in a spot,and goes back, easy.No puzzles.

The upside down bolt needs marked and the one that will not come out must go in before you set the head cover.

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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1431	Re: Engine rebuild must do’s Reply #6 - 01/22/22 at 16:22:55 Clean up exhaust port New cam chain Do something with the tensioner Lap the valves at least, or a real valve job The ultra sexy head plug At least a high compression 94mm piston Open up some of the casting around the spark plug to make it easier to get to Better cam
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REMTB

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Re: Engine rebuild must do’s
Reply #7 - 01/24/22 at 14:29:23

Armen wrote on 01/22/22 at 16:22:55:

Clean up exhaust port
New cam chain
Do something with the tensioner
Lap the valves at least, or a real valve job
The ultra sexy head plug
At least a high compression 94mm piston
Open up some of the casting around the spark plug to make it easier to get to
Better cam

Thanks for the info and tips team, any links for the high compression piston? All I’ve found are old listings for the wiseco pistons?

Cheers

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