SuzukiSavage.com - Got the bad boy out

Toymaker

Serious Thumper

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Dragon Rider

Posts: 1534
Granite Falls, NC
Gender: male

Got the bad boy out
04/24/08 at 17:32:08

Well, I discovered that there was no way for me to get the head off to replace the head gasket without removong the engine. After 30 minutes, Brooke (my daughter) and I got the engine out and on the assembly bench in my shop. Clymer did a good job of breaking everything down to steps, I just hope I can get this thing back together! I am still waiting for my gaskets from JT motorsports, but they told me on tuesday I should have them tomorrow (friday)...I hope so...the weather is supposed to be rainy and I'll need something to occupy my time.

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T Mack 1 - FSO Serious Thumper Alliance Member Offline sold 2001 LS650 for a 1986 XLH1100 Posts: 2919 Emmaus,Pa Gender:	Re: Got the bad boy out Reply #1 - 04/24/08 at 19:03:34 Good luck. I had no one around to help put it in. That bugger is heavy.... and it doesn't fit like that show on that motorcycle tv show... Hint, tape up the frame to prevent scratching it. Just remember, when they say use a wood dowel to xxxx.... tell them to .@#&$^%!*
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Max_Morley Serious Thumper Offline LT650 Luxury Touring & sidecar rig Posts: 1490 Moses Lake. WA Gender:	Re: Got the bad boy out Reply #2 - 04/24/08 at 19:45:13 On my 96 I did not have to pull the engine, just follow the tips in the tech section and let it pivot on the mid back engine bolt, have to remove the front 2 and lower rear one and it tips down far enough to ease the head off and on. I think we can thank Greg for that one. Max
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KwakNut

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SuzukiSavage.com
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Sheffield, England, mostly.
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Re: Got the bad boy out
Reply #3 - 04/25/08 at 02:15:51

I found the head came off easily enough without removing the motor, but the barrel - that was another story.

With mounts loose/bolts out, engine tilted every which way, I just needed about another third of an inch to get the barrel off the top of the head bolts - if anybody has managed that with the engine in the frame, give the man a cigar.

It did at least give me the chance to strip and paint the frame, then the devil's own job getting the motor back in without scratching the newly painted frame rails.

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If everyone is thinking alike, then somebody isn't thinking.
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Toymaker

Serious Thumper

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Dragon Rider

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Granite Falls, NC
Gender: male

Re: Got the bad boy out
Reply #4 - 04/25/08 at 02:25:24

Well the frame on the bottom is a bit grimey and so I also thought that I'd clean it up and all. Also, since I had he head off, I rotated the crank to move the piston to the topof the cylinder. I thought that was TDC...I looked at the factory marks on the alternator side. It is at the 3 o' clock position... Is that right? I thought the marks were to be straight up.

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T Mack 1 - FSO Serious Thumper Alliance Member Offline sold 2001 LS650 for a 1986 XLH1100 Posts: 2919 Emmaus,Pa Gender:	Re: Got the bad boy out Reply #5 - 04/25/08 at 11:37:29 Pretty sure 3 o'colck is right. Can you see the mark on the side case?
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Toymaker

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Granite Falls, NC
Gender: male

Re: Got the bad boy out
Reply #6 - 04/25/08 at 17:40:27

Well after I got the engine on my bench and started putting stuff back on, I noticed that there is a small timing mark on the alternator. Lines up dead straight up and has a matching mark on the case. The timing mark on the bolt IS at 3 0' clock when this mark is straight up. Now I am trying to get the cham chain sprocket back on the cam...

both lobs are supposed to be down,... which means the cam bolts are straight up and down, right? I do have a clymer but some of it is not very good.

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Toymaker Serious Thumper Offline Dragon Rider Posts: 1534 Granite Falls, NC Gender:	Re: Got the bad boy out Reply #7 - 04/25/08 at 19:40:25 Managed to get the cam back on. Then I saw the timing marks on it. I am only off 30 degrees! ehehehe...well tomorrow that will be the first thing to fix. I am really going to know this bike when I am all done. and I thought my mechanic days were over......... yeah right!
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Toymaker

Serious Thumper

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Dragon Rider

Posts: 1534
Granite Falls, NC
Gender: male

Re: Got the bad boy out
Reply #8 - 04/26/08 at 19:13:36

Well, another snafu...one of the gaskets that I ordered isn't the right one. I called JT motorsports and it was their mistake. They didn't have one in stock so they have to order one...will take 4 days but then they will overnight it to me...so with the motorcycle gods smiling, and if I hold my mouth just righ, and if the wind blows out of the north maybe, just maybe I'll get my bike going next weekend.

Frustated......you betcha
ticked off..............yeppers
realizing there ain't nuthin I can do about it............

Cr@p............boy howdy

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Ed L. Serious Thumper Alliance Member Offline "We All go a Little Crazy Sometimes" Norman Bates Posts: 2808 Sunny Florida Gender:	Re: Got the bad boy out Reply #9 - 04/26/08 at 19:19:36 Have a beer and port the head while waiting for the gaskets.
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10875 Oklahoma Gender:	Re: Got the bad boy out Reply #10 - 04/27/08 at 02:48:21 Yea, time flies when we are having fun.
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Toymaker Serious Thumper Offline Dragon Rider Posts: 1534 Granite Falls, NC Gender:	Re: Got the bad boy out Reply #11 - 04/27/08 at 05:55:58 The only thing I can say is that I'll know this engine when I am finished...if I can remember how to put it back in the frame!
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