SuzukiSavage.com - Top end damage and rebuild

Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #15 - 10/24/22 at 17:22:32 Thanks Justin. I'll order that and I should probably organise a new cam before measuring. If they are in spec would I be semi-safe to just smooth them out and keep riding til a new head or repair option is available?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28780 L.A. California Gender:	Re: Top end damage and rebuild Reply #16 - 10/24/22 at 17:28:52 Moarpower wrote on 10/24/22 at 14:36:34: Do you know the range for the clearances ? journal oil clearance 0.0013-0.0026" wear limit 0.0059"
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #17 - 10/24/22 at 17:57:45 verslagen1 wrote on 10/24/22 at 17:28:52: Moarpower wrote on 10/24/22 at 14:36:34: Do you know the range for the clearances ? journal oil clearance 0.0013-0.0026" wear limit 0.0059" Thanks Vers. Is this the same on all of the journals? What are the factory clearances on a new motor?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Top end damage and rebuild Reply #18 - 10/24/22 at 18:04:43 they are in spec would I be semi-safe to just smooth them out and keep riding til a new head or repair option is available? I'm not the guy to answer that. I am the guy who would ask it.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #19 - 10/24/22 at 18:22:19 justin_o_guy2 wrote on 10/24/22 at 18:04:43: they are in spec would I be semi-safe to just smooth them out and keep riding til a new head or repair option is available? I'm not the guy to answer that. I am the guy who would ask it. One way to find out I guess
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verslagen1

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Re: Top end damage and rebuild
Reply #20 - 10/24/22 at 18:26:37

Moarpower wrote on 10/24/22 at 17:57:45:

verslagen1 wrote on 10/24/22 at 17:28:52:

Moarpower wrote on 10/24/22 at 14:36:34:

Do you know the range for the clearances ?

journal oil clearance 0.0013-0.0026" wear limit 0.0059"

Thanks Vers. Is this the same on all of the journals? What are the factory clearances on a new motor?

I would assume the 1st range is new or typical and the 2nd is max

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #21 - 10/24/22 at 19:31:19 Thanks very. It really would suck to have to scrap this bike but it looks like that's on the cards.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4222 Honolulu	Re: Top end damage and rebuild Reply #22 - 10/24/22 at 20:45:55 You obviously must replace the head assembly (head and head cover). The cam is not salvageable. I doubt Web will accept it as a core. I wouldn't consider trying to use the cam. The lobes are heavily scored and the edges of the lobes have actually been rolled over. Impressive considering how hard the material is.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4222 Honolulu	Re: Top end damage and rebuild Reply #23 - 10/24/22 at 20:47:23 Looks like there's even a chunk of the lobe gone.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4222 Honolulu	Re: Top end damage and rebuild Reply #24 - 10/24/22 at 20:48:15 The cam journal is scored. That's why I don't think Web will accept it for a core.
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DragBikeMike

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Re: Top end damage and rebuild
Reply #25 - 10/24/22 at 20:53:48

Considering the starter gear failure, and now these heavily worn rockers and cam, it's apparent that a lot of metallic debris has been circulating all through your engine. It also appears as though it was woefully short on lubrication. You can't have any confidence in the engine.

I would seek out a good used powerplant and install it into your ride. Then, at your leisure, go through the old engine and build a proper hot-rod. It is ALWAYS good to have two engines.

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Moarpower

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Re: Top end damage and rebuild
Reply #26 - 10/24/22 at 20:56:41

DragBikeMike wrote on 10/24/22 at 20:53:48:

Considering the starter gear failure, and now these heavily worn rockers and cam, it's apparent that a lot of metallic debris has been circulating all through your engine. It also appears as though it was woefully short on lubrication. You can't have any confidence in the engine.

I would seek out a good used powerplant and install it into your ride. Then, at your leisure, go through the old engine and build a proper hot-rod. It is ALWAYS good to have two engines.

I agree Mike. I have begun the search for a used motor and contacted every motorcycle machine shop within 200kms to see about resurfacing the cam journals. . I have a Honda vlx 600 to work on while i wait. I'd hate to scrap the savage but they just aren't common bikes here so I'll keep hunting.

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #27 - 10/25/22 at 00:28:01 Hi guys. I have found a motor for 600aud. He is going to open it up and check the head for me. It's a 2001 and mine is an 87. Is there anything I'd need to change ?
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Yazman Full Member Offline SuzukiSavage.com Rocks! Posts: 131 Ohio Gender:	Re: Top end damage and rebuild Reply #28 - 10/25/22 at 06:05:33 FWIW, I was having similar issues on my Rebel 250, and the full engine swap ending up being the way to go. Immeasurably easier and less frustrating. I spent weeks trying to repair my old engine, took an hour to swap in a new, running unit.
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Moarpower

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Re: Top end damage and rebuild
Reply #29 - 10/25/22 at 06:27:54

Yazman wrote on 10/25/22 at 06:05:33:

FWIW, I was having similar issues on my Rebel 250, and the full engine swap ending up being the way to go. Immeasurably easier and less frustrating. I spent weeks trying to repair my old engine, took an hour to swap in a new, running unit.

Im definitely on the hunt for a complete motor but my chances are very slim

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