SuzukiSavage.com - R&R Cylinder Head with Tech Assist

ThumperPaul

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Re: R&R Cylinder Head with Tech Assist
Reply #375 - 01/04/24 at 16:50:31

It’s just hard to watch! Shocked

I’m at a standstill right now waiting for a few o-rings and a longer clutch pushrod. It appears I need the 46.5mm length. I want to compare to the 45.5mm before making a final decision. I’m pretty much wrapped up with everything else. Parts due by Monday. It’s been too long. Some were on back order from Suzuki (apparently in Japan taking the slow boat by the pace of things). Holidays bogged things down too.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: R&R Cylinder Head with Tech Assist Reply #376 - 01/04/24 at 17:27:58 they're cheap order all 3 lengths. measure how long they stick out of the spider, 13mm is too long, 12mm is the shortest I'll use.
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ohiomoto

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Re: R&R Cylinder Head with Tech Assist
Reply #377 - 01/04/24 at 18:35:43

Dave wrote on 01/04/24 at 12:30:17:

I just found out you don't need to remove the cylinder stud after all.

Go to 26 minutes for the fun!

https://www.youtube.com/watch?v=qyaLdxhtvjk&t=1572s

---------------

That's just the farmer's version of DBM. IDK, I guess the LS650 has "tractor-like" power. His work might be good enough.
Shocked

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #378 - 01/05/24 at 17:05:28 Thanks Verslagen. Good info!
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ThumperPaul

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Re: R&R Cylinder Head with Tech Assist
Reply #379 - 01/07/24 at 11:02:00

DragBikeMike wrote on 12/18/23 at 14:57:16:

From this point, the clutch basket just pulls off the transmission input shaft. There are two thrust washers and a spacer associated with the clutch basket. The smaller washer goes between the clutch hub and the basket. That would be the washer shown here.

When reinstalling the clutch, is it a good practice to put some engine oil on the 2 thrust washers, bearing, and transmission shaft?

The final parts needed should finally arrive tomorrow and thinking ahead to reassembly on Tuesday.

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Dave

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Re: R&R Cylinder Head with Tech Assist
Reply #380 - 01/08/24 at 03:30:28

Yes, you should have a light coating of oil on the shafts and thrust washers and anything else that moves/rubs against other parts. The drive gears don't need lubed as the big gear will dip into the oil once you fill up the crankcase.

I have often thought that maybe "overfilling" the crankcase to put a coating of oil on parts before the startup (when an engine has been down for an extended period) might be a good idea - you would then drain the excess and fill the crankcase to the proper level prior to starting the bike. I realize it may be "overkill" - but I don't see how it could hurt anything.

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ThumperPaul

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Re: R&R Cylinder Head with Tech Assist
Reply #381 - 01/08/24 at 05:14:53

Thanks Dave. That makes sense. The thought of dry starting is concerning to me as well. Before I put the valve inspection covers on, I’m going to slowly add 4-5oz of fresh oil up top. I was also planning to “prime” my new dry oil filter (get it wet). I don’t want it acting like a dry sponge. Then oil fill with 2+ quarts of oil as normal at the crankcase.

If I recall correctly, it takes a total of 2.3 quarts after a rebuild. Can you confirm?

EDIT: Looks like 2.4 LITERS (2.54 quarts) total capacity after a rebuild or dry state.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: R&R Cylinder Head with Tech Assist Reply #382 - 01/08/24 at 09:40:46 here's a tip for you... remove the timing plug and the oil will drain to the right level on the sidestand.
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DragBikeMike

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Re: R&R Cylinder Head with Tech Assist
Reply #383 - 01/08/24 at 10:00:10

Paul, in addition to lubricating the clutch spacer and thrust washers, you should also dip each clutch plate (steel & fiber) in clean oil before you assemble the clutch.

When you first start the engine, it will run ten to twenty seconds before any oil reaches the top end. That's hard on the cam & rockers. You want to make sure the oil reservoir for the cam lobes is full of oil before you crank the engine.

That would be this reservoir. You need to fill this reservoir using a small hose. Red arrow shows the path that the hose must run.

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Fill_Oil_Reservoir.jpg

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4471 Honolulu	Re: R&R Cylinder Head with Tech Assist Reply #384 - 01/08/24 at 10:02:55 Use a pump-type oil can or a suitable squeeze bottle. Run the hose through the intake valve side, under the rocker arm, and into the reservoir. You can see when the reservoir is full by looking through the opening in the head cover.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4471 Honolulu	Re: R&R Cylinder Head with Tech Assist Reply #385 - 01/08/24 at 10:07:13 See how the small clear plastic hose is routed under the rocker arm. It has to go all the way into the reservoir. Just squirting oil in through the openings will not help much. The oil will just run down the drains. You must fill the reservoir.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4471 Honolulu	Re: R&R Cylinder Head with Tech Assist Reply #386 - 01/08/24 at 10:12:50 You also want to put a coat of oil on the end of the crankshaft where it runs in the oil seal. The oil seal is in the clutch cover, and the crankshaft runs in that seal. Coat the end of the crank with oil, and also coat the oil seal with oil.
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2642 Amongst the Twisty Roads	Re: R&R Cylinder Head with Tech Assist Reply #387 - 01/08/24 at 12:16:46 I use assembly lube (Lucas) on just about everything when I reassemble an engine...and I'm not shy about how much I use. I also will remove the spark plugs and crank the engine over for about 30 seconds so the oil pressure builds up a bit before my first start.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #388 - 01/08/24 at 12:30:57 Thanks guys!
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2156 Houston, Texas Gender:	Re: R&R Cylinder Head with Tech Assist Reply #389 - 01/08/24 at 13:58:57 PS - should the clutch cover gasket get a coating of grease or oil, or just keep it dry?
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