SuzukiSavage.com - Top end damage and rebuild

TheSneeze

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Re: Top end damage and rebuild
Reply #30 - 10/25/22 at 10:45:22

Moarpower wrote on 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 ?

I know the main difference is the '01 is a 5 speed trans, yours is a 4 speed. This is what the late model rockers look like. That is a new cam for a '95 DR650 (more lift and duration than a Savage).

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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: Top end damage and rebuild Reply #31 - 10/25/22 at 10:48:23 This is what I found when I opened up my cam cover. It was a non-running bike when I got it. Luckily the cam journals were fine, only the rockers and cam lobes were shot.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: Top end damage and rebuild Reply #32 - 10/25/22 at 10:51:08 On the pic of the new rockers you can see the hardened pads they upgraded to. Obviously Suzuki was correcting a design flaw with the earlier rockers.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #33 - 10/25/22 at 15:49:34 How well does the bike run with the dr650 cam? The engine I found for 600 is no good so the search continues. It might be a long time so I'm going to cancel the registration.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: Top end damage and rebuild Reply #34 - 10/25/22 at 15:59:02 My motor is in pieces on one of my work benches. I have 98% of what I need to start the reassembly process, but need to paint my engine cases. So, short version is I don't know yet. But DragBikeMike has a lot of info and details of using this cam in is "how to hotrod" threads.
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Moarpower

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Re: Top end damage and rebuild
Reply #35 - 10/25/22 at 21:18:05

I have spoken to many machine shops and top end specialist with only one person willing to try something. He suggested if there is enough surface left on the journals, decking the head and/or cap slightly to get everything running within tolerances. This could get me riding for a while longer while I search for a replacement head or engine

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Moarpower

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Re: Top end damage and rebuild
Reply #36 - 10/25/22 at 21:41:25

I have also spoken to a workshop 3 hours away. They are willing to help with welding and line boring for around 500 AUD.
With a new cam and rockers, Id still make a profit on the bike if I do decide to sell it.

If I decide to keep the bike, this issue has me wondering about running an external oil pump. While I am sure user error is to blame in the first place Id love to be able to go on a multi-hour ride feeling confident in my engines oil flow

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #37 - 10/26/22 at 00:19:15 I have found a LS400 being parted out. From what I can find, and that is very little, the parts may be interchangeable as far as the head goes. Any one able to clarify?
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Dave

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Re: Top end damage and rebuild
Reply #38 - 10/26/22 at 03:27:09

Moarpower wrote on 10/26/22 at 00:19:15:

I have found a LS400 being parted out. From what I can find, and that is very little, the parts may be interchangeable as far as the head goes. Any one able to clarify?

The LS400 head is the same except it does not have the compression release shaft.

The piston and cylinder bores is smaller and the rod journal is smaller by 1mm.....you would not be able to make a 650 by using the larger 94mm piston.

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Someday I will be old......But not today!

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #39 - 10/26/22 at 03:44:19 Thanks Dave. All I'd be needing was the head assembly with the cam a rockers. not the cylinder. I'm assuming if it doesn't have the decomp it's not going to work?
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #40 - 10/26/22 at 04:09:27 I do have a 400 head I can buy. I wonder if I can make it work if I had a shop machine the 400 head to mount the decomp. Or if I could make something else work.
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Moarpower

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Re: Top end damage and rebuild
Reply #41 - 10/27/22 at 14:59:54

Hey guys, so so far my only option is to buy a 400 head. Is it possible to make the decomp work on these if I was to take it to a machine shop? I know no one is probably done it But without having it in hand to look at as it's coming from New Zealand, I'd assume that's Suzuki try to save money by simply using the same casting and just not boring out and threading the holes necessary. What do you think?

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Dave

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Re: Top end damage and rebuild
Reply #42 - 10/27/22 at 16:42:45

If you live in a warm climate and keep a fresh battery - you may be able to get by without a compression release.

I have a higher compression Wiseco piston and a manual compression release - and most times my bike starts just fine without me using the compression release. About 1 in 100 starts the piston is on the compression stroke when I push the start button and the starter can't push the piston over TDC.

With a stock piston I believe you will not have an issue.....as long as you don't ride in freezing weather that causes thick oil and poor battery power.

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Someday I will be old......But not today!

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Top end damage and rebuild Reply #43 - 10/27/22 at 17:03:10 Thanks Dave. I'm based in Australia so I will never really get too many cold days but I am probably going to have to bore out to a 95 mm as the sleeve is at the higher end of its tolerance
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Moarpower

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Re: Top end damage and rebuild
Reply #44 - 10/27/22 at 22:25:56

Still no luck on replacement parts or a full engine. If any of you guys happen to have the spare parts please let me know.

I was going to give up and part out the bike. But If i cant get the parts I'll turn it into something else and modify the frame for a 4 cylinder. I'm handy with a welder so it could be a fun project once my shoulders better after yesterdays surgery

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