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Reassembly after inspecting cam (Read 72 times)

Moarpower

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Reassembly after inspecting cam
08/27/23 at 21:18:51

Hey guys.

I opened the top of the engine to inspect the cam and valves and I removed the cam.
I was just wanting some tips on reassembly. I have the manual but wasn't sure exactly what to do.
Is there a way to reassemble without removing the clutch cover to ensure the cam chain is on the crank ? Also, finding tdc on the compression stroke isn't really easy with the rockers off.

I know to line up the marks on the cam itself level with the head surface. But with which lobe facing upwards? Or does it not matter?

Sorry for the noob question. Just a little confused about what I need to do and want to make sure before I order a new clutch cover gasket.

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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28890 L.A. California Gender:	Re: Reassembly after inspecting cam Reply #1 - 08/27/23 at 22:19:08 TDC both lobes facing down (that's compression stroke), alignment pin at 1 o'clock, marks on the end of the cam horizontal. if you have a used chain, the forward mark will be up a bit. you need to remove the clutch cover.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Reassembly after inspecting cam Reply #2 - 08/27/23 at 22:21:09 Thanks Vers. So just line the crank bolt up with the mark at 3 o'clock and set the cam as you've suggested and I should be sweet? Have a new clutch cover gasket coming. I'm going to make a bunch of my own using gasket material because I pull this bike apart a bit and I'm always waiting for gaskets.
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Dave

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Re: Reassembly after inspecting cam
Reply #3 - 08/28/23 at 04:04:16

Moarpower wrote on 08/27/23 at 22:21:09:

Have a new clutch cover gasket coming. I'm going to make a bunch of my own using gasket material because I pull this bike apart a bit and I'm always waiting for gaskets.

While it is not unusual for an old battle hardened gasket that has been in place for many years to tear when you take the engine apart - you should not need a new gasket every time you take the engine apart.

In another recent thread Verslagen and I suggested that putting a light coat of oil on the gasket keeps it from sticking and allows you to take the engine apart and the gasket remains in one piece. I do this on the left and right side case cover gaskets, and I only put oil on the side that does not have the factory applied grey sealant. (I do not put any oil on the cylinder base gasket).

I never apply any type of sealant to the gaskets.....the left and right side will get a light coat of RTV on the rubber plugs that have the electric wires passing through.

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

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Reassembly after inspecting cam Reply #4 - 08/28/23 at 04:35:48 No reason not to replace the o ring the clutch rod goes through. It's irritating to get it together and see That is dripping. Mine did it, it wasn't dripping before it came apart.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Reassembly after inspecting cam Reply #5 - 08/30/23 at 17:40:17 Thanks Justin. I think I actually have a small leak through the sensor wires too that I might try to sort out before getting it all back together.
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Dave

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Re: Reassembly after inspecting cam
Reply #6 - 08/30/23 at 18:15:43

Moarpower wrote on 08/30/23 at 17:40:17:

Thanks Justin.

I think I actually have a small leak through the sensor wires too that I might try to sort out before getting it all back together.

What sensors?

The right side (clutch) has a single wire that is the neutral light.

The left side (magneto) has the power wires and the ignition timing module.

You can seal those by cleaning the oil off them, and applying a very light smear of ATV sealant (black is the least visible).

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

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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Reassembly after inspecting cam Reply #7 - 08/31/23 at 23:31:05 Hi Dave. The right side neutral sensor may have cracked wiring that I need to remedy.
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