| Motor Tear Down and Rebuild A complete resource for engine modifications and repair. |
Welcome to the TLZone forums. TLZone is a forum dedicated to the Suzuki TL1000S and TL1000R series of motorcycles, and is the largest and most popular online bulletin board to discuss all things TL related. Not only is TLZ the place to come to talk about bikes, but has also become a strong community of bikers who share interests outside of riding.
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TLZone Commercial Vendors.
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03-26-2009, 06:34 PM
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#41 (permalink)
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Silver Subscriber
Member #2058
Posts: 3,820
Join Date: Feb 2004
Location: Eureka ca A.K.A=The Friggn BOONIES
Sportsbike: TLS-THE DEADSEXY ONE!!
Riding Experience: 22 yrs riding street
Pictures: 0
Life Wasted on TLZone: 1 Week, 5 Days and 3:59:26 Hours
zippytlsr
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Sooooooooooooooo...... Billet Gears would be stronger right.. So it could potentially keep the gears from just letting go right?
__________________
Scorpio SE-i500 system,TLR MOTOR, pc2,yosh full system w/titanium cans ,(thanks 00tiller) k+N filter, UFO tail light kit-sweet! Corbin seat,Heli Bars, Throttle miester, six pot tlr caliper system, dble bubble screen,Galfer ss brake lines front&rear,tl tank protector,Bitubo rear shock-thanks Origin8tor!,clear clutch cover, CRG Levers,clear tailight lens-new paint, front end reworked by Aftershocks, fresh Powdercoated rims and front Wave rotors via TODD at Cal sportbike,as well as a SPEEDO HEALER from him,  ,fan mod-thanks et79,gpi gear indicator w/ATRE-thanks again cal sportbike. MY CUSTOM R/R WIRING HARNESS TO GET CHARGING SYSTEM UP TO PAR! check frequent mod section out!!
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03-26-2009, 06:43 PM
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#42 (permalink)
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Silver Subscriber
Member #12363
Posts: 6,148
Join Date: Jan 2008
Location: Brisbane Qld
Sportsbike: TL1000s naked
Riding Experience: 35 years
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Life Wasted on TLZone: 3 Months, 2 Weeks, 1 Day and 18:22:36 Hours
The Ring-In
No longer a rain god
butI'm still a C***and a
tool
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Factory gears are made from sintered metal powder. powdered metal is put in a mould and pressed to set it . it it then treated in a furnace to fuse the powder into solid metal and impart the properties required to make it suitable as a gear.
this process ensures the correct dimensions and the correct material structure for the purposes of the gear.
the grain structure of a "billet " of metal does not necessarily have the correct properties for use as a gear.
nor can it guarantee the correct tooth shape once machined to interface correctly with the other gears in the box.
custom gear boxes are indeed made , they are usually for drag use and such things as smoothness of operation and running noise is not a consideration.
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Cheers Stu
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Got to love the Zone, where else can you get Zen levels of wisdom and your ECU remapped, all for free
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.....133bhp
oggi knobs. anodised barends, polished and machined GSXR1000 top triple with Helibars, single 7' headlight. arrow cans, custom rear peg mounts, white power shock and spring centre mounted on R swing arm, painted frame, polished lower gsxr1000 triple,K7 gsxr1000 forks, hugger, undertail, clear tail light lens, PC 11 , modded airbox, K&N air filter, radial calipers, braided front lines, polished rims and black painted wheel spokes, fan override switch , TRE, tank bra, american high capacity battery, gsxr1000 front guard. tlr gauges, rifleman CCC ,van reservoirs,custom overflow bottle, ducati 999 curved radiator, conventional mirrors, machined and polished clutch pressure plate, welded clutch cam mechanism. stainless brake rotor bolts. ring-in stainless exhaust bolts with brass nuts.
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03-26-2009, 06:49 PM
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#43 (permalink)
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Silver Subscriber
Member #2058
Posts: 3,820
Join Date: Feb 2004
Location: Eureka ca A.K.A=The Friggn BOONIES
Sportsbike: TLS-THE DEADSEXY ONE!!
Riding Experience: 22 yrs riding street
Pictures: 0
Life Wasted on TLZone: 1 Week, 5 Days and 3:59:26 Hours
zippytlsr
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WOW... thanks for the education. I had no idea my gears started out as powder.. ugh. 
The info you provided  Was very insightfull!!
Ok, so for daily street use... your saying that the Billet would not be good. If that IS the case.... is there any kind of process we could do to make the gears harder/better... any kind of heat treatment that may help them endure the thrashing we love to give them? 
__________________
Scorpio SE-i500 system,TLR MOTOR, pc2,yosh full system w/titanium cans ,(thanks 00tiller) k+N filter, UFO tail light kit-sweet! Corbin seat,Heli Bars, Throttle miester, six pot tlr caliper system, dble bubble screen,Galfer ss brake lines front&rear,tl tank protector,Bitubo rear shock-thanks Origin8tor!,clear clutch cover, CRG Levers,clear tailight lens-new paint, front end reworked by Aftershocks, fresh Powdercoated rims and front Wave rotors via TODD at Cal sportbike,as well as a SPEEDO HEALER from him, ,fan mod-thanks et79,gpi gear indicator w/ATRE-thanks again cal sportbike. MY CUSTOM R/R WIRING HARNESS TO GET CHARGING SYSTEM UP TO PAR! check frequent mod section out!!
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04-03-2009, 12:43 AM
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#44 (permalink)
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The Suck, Squeeze, Bang, Blow Moderator
Member #2130
Posts: 9,849
Join Date: Mar 2004
Location: York, Ooop North in England
Sportsbike: 3 TLS's, 06 ER6-F
Riding Experience: 33 Years & Still Counting
Pictures: 1
Life Wasted on TLZone: 2 Months, 4 Weeks, 1 Day and 14:54:18 Hours
Sam
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Finally finished last night and got it running again with a week to spare 
Aswell as the engine rebuild it now sports 1mm squish, dialed in Kent Cams, 6 Spring Clutch, Later rear cam cover and breather setup, modded airbox, new chain and sprockets etc
.....oh and an intermittent broken wire to the Airbox sensor which kept throwing C21 codes 
Should be quite a perky little thing now 
I'll take the weekend off before starting the next engine  |
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04-03-2009, 06:09 AM
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#45 (permalink)
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Just call me Ragnar Danneskjöld
Member #2079
Posts: 24,453
Join Date: Mar 2004
Location: Cambridge MA
Sportsbike: 97 TL1000S, 01 CR250R, 96 DR350SE
Riding Experience: 14 years
Pictures: 0
Life Wasted on TLZone: 3 Months, 3 Weeks, 4 Days and 14:25:17 Hours
BikePilot
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great work Sam. Do you fancy a trip to DC, my TLS could use a little TLC
Zippy, I think there are some companies that will treat gears to supposedly make them harder. You can also have the gears undercut which is supposed to help, but I think the biggest thing is to not bang about on the shift lever like a mad man and to stop and fix the bike whenever anything starts acting up. If its popping out of gear, tear it down and fix before two gears decide they'd like to play at once
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Josh
TL Zone Forum Staff - Resident RAIN RIDER
Questions about The Forums? Click Here
1997 TL1000S/V
- TLR Akro Evo Ti Exhaust - PCII - 5.5" rear rim & 180/55 - Avon AV45/46ST tires - No Steering damper- Uni Filter -Relocated Temp sensor & 98+ t-stat housing/wp cover - TLRCrazy1 Fan Switch Mod - Dual Star heated Grips - HeliBars - 60k miles.
9k mile summer ride report [summer '08]
Ride report: Oshkosh, Rockies, UT, NV, CA, Bajal [summer '09]
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04-03-2009, 09:21 AM
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#46 (permalink)
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Resident 100HP Water-Cannon Operator
Member #1415
Posts: 8,533
Join Date: Nov 2003
Location: Leicester, MA
Sportsbike: 05 Kawi SX-R800 stand-up jet ski
Riding Experience: 11dirt/8street/3water ;)
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Life Wasted on TLZone: 3 Months, 3 Weeks, 0 Days and 17:21:43 Hours
TLR-Billbo
is dreading winter coming
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Quote:
Originally Posted by BikePilot
Zippy, I think there are some companies that will treat gears to supposedly make them harder.
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 they cryo-treat them, been doing it for years in the diesel performance industry for tranny and diff gears
__________________
* 2005 SXR 800*Skat 9/17 140-75 SS Impeller*Blowsion mat kit*Blowsion billet bilge switch*Rule 500GPH bilge*R&D bilge bracket*R&D billet angled reed spacers*V-Force Delta 2 Carbon reeds*R&D exhaust sleeve*Wamiltons scupper*Wamiltons stubby pump cone*fuel fill and pickup mod*-4" hull*-1.5" pole*R&D stealth intake grate*-4" ride plate*ODI grips*R&D Pro-lock filters*Jetworks mixture screws*Blowsion billet engine mount keepers*R&D 6º ignition adv kit*Billet driveshaft coupler*dual-cooling*Wiseco 80.96mm factory Kawi race pistons (true 800cc)*UMI Billet throttle lever*
Still To Come:*Factory Wet Pipe*AC Racing pole*footwells*new mats*
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Quote:
Originally Posted by Shrek
Hey Bilbo, maybe you can get your BSTs chromed. There is that guy on Ebay that can chrome anything. Then you'll have the best of both worlds. After they're chromed, you can add accents to them with that vinyl carbon sticky tape! That would be so hot. You'd get all the chicks at the bar without even taking the bike off the trailer!
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04-08-2009, 06:13 AM
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#47 (permalink)
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Silver Subscriber
Member #2058
Posts: 3,820
Join Date: Feb 2004
Location: Eureka ca A.K.A=The Friggn BOONIES
Sportsbike: TLS-THE DEADSEXY ONE!!
Riding Experience: 22 yrs riding street
Pictures: 0
Life Wasted on TLZone: 1 Week, 5 Days and 3:59:26 Hours
zippytlsr
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@Bike Pilot.... yes.. IF I EVER have trans trouble again I will stop everything as soon as safely as possible. Unfortunately when i destroyed my 3rd/4th gears it was instant.. and again... instant on the second time.
@Tlr-bilbo Thanks for the info... do you know of who might do that service? Do ya have a link? It would almost be worth taking my motor apart for a 4th time to send the bits off and have them treated. I will definetly send my other motor bits off when i "build" it. 
THe last time my motor was apart... i did have the trans undercut and put in the new shift star and shift detent arm from Factory Pro.
__________________
Scorpio SE-i500 system,TLR MOTOR, pc2,yosh full system w/titanium cans ,(thanks 00tiller) k+N filter, UFO tail light kit-sweet! Corbin seat,Heli Bars, Throttle miester, six pot tlr caliper system, dble bubble screen,Galfer ss brake lines front&rear,tl tank protector,Bitubo rear shock-thanks Origin8tor!,clear clutch cover, CRG Levers,clear tailight lens-new paint, front end reworked by Aftershocks, fresh Powdercoated rims and front Wave rotors via TODD at Cal sportbike,as well as a SPEEDO HEALER from him, ,fan mod-thanks et79,gpi gear indicator w/ATRE-thanks again cal sportbike. MY CUSTOM R/R WIRING HARNESS TO GET CHARGING SYSTEM UP TO PAR! check frequent mod section out!!
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04-30-2009, 05:13 PM
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#48 (permalink)
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Silver Subscriber
Member #778
Posts: 5,474
Join Date: Jun 2003
Location: Islington boy, but living in Docklands, london 07540588983
Sportsbike: RED 97 TLS with exstensive mods
Riding Experience: 9 (1000s in my dreams)
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Life Wasted on TLZone: 1 Week, 0 Days and 19:16:02 Hours
PAPPACLART
Just tripped over his
middle leg
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Wow good read
I thought I got over my paranoia of engine self destruction but my fears have come all back with vengance!!!
My old Girl has just over 50,000 hard miles with little servicing. She is bounced of the limiter most days 
Though since I have owned her, not once has she ever jumped out of gear  hopefully that is a good sign?
Sam I know you hate me now because I am not letting go of my Yosh, but will you Pretty please rebuild my motor when it goes bang?
PS
Is TL monkey still about, because when I was at his place a few years back I remember is garage having enough TL engine parts to build about 30 motors, seriously , he had tons of stuff..maybe he has cunning money making plan
__________________
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''Knowledge is just a tool to exploit the intelligence you are born with''
Famous Quote from Professor Pappaclart - MA, MBA, CBD, ABC, 123 , A++, D Minor, Prof of Retardation
''Born a natural loser, can't recall just where... Raised on pool and poker and a dollar here and there.... Blackjack hand, dealer man, you'd better pay off that last debt.... Two-bit hand, a 21, is all I ever get.... Go down gambling, say it when you're running low, Go down gambling, you may never have to go Down in a crap game, I've been losing at roulette Cards are bound to break me, but I ain't busted yet 'Cause I've been called a natural lover by that lady over there..... Honey, I'm just a natural gambler but I try to do my share''
''All I ask of living is to have no chains on me And all I ask of dying is to go naturally Give me my freedom for as long as I may be''
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04-30-2009, 07:12 PM
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#49 (permalink)
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Silver Subscriber
Member #2639
Posts: 16,589
Join Date: May 2004
Location: Eastern USA
Sportsbike: none
Riding Experience: not enough
Pictures: 10
Life Wasted on TLZone: 2 Weeks, 3 Days and 18:44:43 Hours
deltl1ks
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to tlr tech |
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04-30-2009, 10:20 PM
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#50 (permalink)
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The Suck, Squeeze, Bang, Blow Moderator
Member #2130
Posts: 9,849
Join Date: Mar 2004
Location: York, Ooop North in England
Sportsbike: 3 TLS's, 06 ER6-F
Riding Experience: 33 Years & Still Counting
Pictures: 1
Life Wasted on TLZone: 2 Months, 4 Weeks, 1 Day and 14:54:18 Hours
Sam
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Quote:
Originally Posted by PAPPACLART
Sam I know you hate me now because I am not letting go of my Yosh, but will you Pretty please rebuild my motor when it goes bang? |
Of course, doing two more Zone members engines as we speak |
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