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Shes about ready to drop like 9 month fetus!!!

17700 Views 133 Replies 18 Participants Last post by  rxf610, 
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I suppose I should have started my last thread here so I'll continue the thread I started in the help section.

So I've about got my engine ready to drop. I did go ahead and pull the throttle bodies all the way out just to clean it up a bit. I've got 2 pages left in the service manual. Should I go ahead and pull the flywheel, clutch basket, and crank bolts while its in the frame? Leverage will not be easy to obtain once its out and I don't have an impact or an engine jig. I can take it to an impact once its out but unless I really need to I won't . I'm sure I'll need a new crank, especially considering how many times I unlocked, started it, and locked it back up. Last time it locked I couldn't get it unlocked so that will help when I pull the basket and flywheel, not so much when I pull the crank. I have no intention of turning the 97 crank. I'llpick up a second hand 98 or later crank somewhere (per The Ring-In's instruction) The ONLY way Iwill reuse this crank is if its undamaged and that aint likely. So hopefully I'll have it apart buy tomorrow. I'm sure everyone is on the edge of their seat with popcorn in hand waiting to see what the diagnosis is . I'll have pics up asap.........
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Brainless
Ever thought of getting a whole used motor and just swap? Might be cheaper than rebuild... :O (pretty sure it is...)
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Ohhhhhhh yeah! I fully intend to put a tlr engine just as soon as this one is cashed out. I'm not gonna do a full rebuild. I'm not gonna touch the heads or transmission unless I get in their and see bad damage. I just can't afford to right now. I ll probably put new head gaskets on, I'll do what u guys think best on that one. All I'm planing on is crank, bearings, and rings if needed. I know the pistons have been lubed good, I poured a shit ton of oil in the cylinders after it locked the first time, again I'll go with u guys judgement on the rings. I would love to do a a full rebuild but I just don't have the money right now and won't for about 6 more months. In six months I'll be rolling in it again and I'll get me a tlr engine or maybe an sv engine. I haven't researched the sv yet but I like the way it looks. So if I can get one season out of it I'll be happy. It's only got 44,000 miles and it's clearly been taken care of and the previous owner did not dog, hell he didn't even ride it, the chicken strips are like 3 inch's wide. Just one 2 inch strip down the middle.
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Ok I guess I've cursed myself. I can't find a crank anywhere for less than $300. Looks like I may have to have mine repaired. That's damn near my whole budget for this rebuild. So tell me Ring, what's a set of oversized bearings cost and how long from down under? So do u tell me what to have it cut to or do I tell u what they cut it to? I trust you not steering me wrong so I think it would be worth waiting a bit, I been waiting this long.
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2
[SUP][/SUP]Well it's out. Didn't get to work on it much yesterday so I finished it up this morning. I think i will take it to a friends house to tear it down. My girl is about ready to kill me for doing this inside but **** it's cold outside and it's pouring rain. My friend has all the tools and shit I need. Ironically it's the guy I got the bike from. Probably take it over there Monday. Hopefully i can get it done in one day.

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Found a set of tlr rods and pistons for $99. Don't know if I'll need them yet but that's a good price I suppose. I was really shocked to find a serious lack of tl parts available. Hell u can get a gsxr 1000 rebuild kit with pistons, rods, bearings, oil pump, seals, gaskets and everything else u need for less than $500 USD. You can't find a kit PERIOD for a tl engine. Buying all these parts seperate is gonna kill me. , $80 for head gaskets, $40 oil pump, $50 bearings(?), plus whatever else I need and machine shop work. I'd like to just get it all in a kit so I could replace everything that may need it.
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D
dont quote me on prices, but i belive ive seen whole engines go for around the 4-500 dollar mark right here on theese forums...i really think you should just wait for the donor motor, you might want to check out TLP as well
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I joined tl planet a week ago and they still haven't approved my account. I even put The Ring-in as a referral and still nothing. I have not seen any engines for sell here unless u count a €4000 1080 bigbore engine. I can get a engine for $700-$800 but I feel certain I can get it going for less than $500 usd. What is their really to replace? I probably won't need pistons, rods maybe but their pretty cheap. Bearings are around $50 from what I've seen, not sure about oversized bearings but surly their not much more. What's it cost to turn a crank? I don't see any damage to the cams. They don't appear to have ever been oil starved. Oil is pooled in the corners and their is no metal in their so Im pretty sure the heads are ok. Head gaskets are about $70. Rings are about $60 I think and a 98 or later oil pump can be had for $40. What else is there to replace? There is not many seals and gaskets to replace. Did I miss anything?
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Started tearing it down this morning. So far I've got the heads and the hugs off. I'm about to pull the clutch, flywheel, and crankshaft sprockets. I have descovered that the rod bearings are where it's locked up at. I can't get the pistons up enough to pull the pins. They will rock back and forth but hey won't move on the crank. There both locked. The jugs look great. The hone marks are clearly visible and no lip. Same thing with the heads, no obvious damage so maybe I lucked up. Back to work I go.


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Well, it's just about ready to split. I believe all I have left to come off is the flywheel. I have a vague idea how it comes off. If anybody has a picture of the tool used to pull the flywheel that would help a lot. I'm hoping that since it's locked up at the rods the big ends will be ok and if the rods are locked hopefully the rods will be damaged and not the crank, hey it could happen. So far everything else is going my way. I am a bit concerned tho. I notice quite a bit of lateral movement in the crank. It moves side to side quite a bit. Guess well see. I guess if I can't get the flywheel off I'll take it to a shop and get them to pull the flywheel and split the case. I'll post some updates as they come if anybody cares, if not this will be my last post on the topic. No point in talking to myself.



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The Ring-In
you need a 20mm x 1.5mm bolt to remove the flywheel

the rear axle on the katana is probably the right size.

remove it and try it
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Thank you Sir! So I just thread the bolt thru and it pushes it off?
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Katana??!!! What katana? I don't have a katana but if it works I'll go to the suzuki store and get the bolt.
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762fmj
Felipe said:
.... I'll post some updates as they come if anybody cares, if not this will be my last post on the topic. No point in talking to myself ....
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You keep it up pal ... I'm very interested ... I admire anyone who has the temerity to have a go ..... No matter what anyone says we all learn something from the process. BTW look after that lady of yours ... agreeing to a full bike rip down in the house is priceless. I got bollocked yesterday just for polishing my new cans in the kitchen. :rolleyes
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762fmj said:
You keep it up pal ... I'm very interested ... I admire anyone who has the temerity to have a go ..... No matter what anyone says we all learn something from the process. BTW look after that lady of yours ... agreeing to a full bike rip down in the house is priceless. I got bollocked yesterday just for polishing my new cans in the kitchen. :rolleyes
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Thank you very much Sir! Yeah she's a trooper. Fortunately were about to pull up the carpet anyway, it's hardwood under it so she knows I'll hurry up and strip the carpet if I get it nice and greasy first lol Thanks for the encouragement. I've tore a few motorcycle engines down but I've never attempted to put one back together, not by myself. Their is just so much crap you don't have on a automobile engine. I mean hell on a car engine u pull the head, u pull the pan, u pull the crank, that's it. If it was a honda b or h engine I would be putting it back in tomorrow. I just hope I get it all back together right. The pictures in the book suck ass! Fortunately I didn't break or strip anything when I tore it down. I can't wait to get to the crank. I'll feel much better when I split the case.
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The Ring-In
the rear axle from the other Suzuki you have. is a prospect.

wind it in tight and hit the end with a hammer and the flywheel should pop off
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The only bike I have is the TLS. I can just take it to the dealership (not the one that ****ed it up) and try a couple different ones. If a katana works I'll try a few of those. Buying the bolt is still cheaper than having them do it and I'll have it when I need it again. I greatly appreciate the info. One more question, what do I us to reseal the crankcase?
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The Ring-In
20mm bolt with 1.5mm thread is the go

needs a special bolt shop not a hardware store
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The Ring-In
what do I us to reseal the crankcase?
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"3bond" from a bike shop
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Thank you once again my good man! I will get my hands on some 3bond and I will see about getting that bolt, shouldn't be a problem. The help is much appreciated.
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