In for a pound

[kawonda750]

Picked this up today. Engine is free. Everything is there except the chain guard. PO took it to Alaska so he installed the enclosed chain thingee. I will not keep it.

Lester wheels and I got the spoked originals too in very good shape. Something to do in the long winter... It's a 1975 btw.

[kawonda750]

I opened up the fuel lid and found gasoline turned to brown mud. The cleaner solution has been in for 24 hours now. I'll give it another 24 then have a looksee and assess it.

[kawonda750]

The tank inside is very bad. I used the Creem liner first solution and it has improved slightly. Next it was vinegar soaking for 4 days and then put about 18 inches of chain in and shook her up. Again slight improvement but , with the shallow depth at the front of the tank it was difficult to get the chain out. Eventually I had to go fishing with a an extending magnet to finally get it. So, next time it will be nuts instead of chain. Now soaking with an Evaporust knock off to see what that will do. Otherwise, it may be searching for another tank.

[kawonda750]

I was forced to buy another tank. The original did not come anywhere close to clean after 3 tries with 3 different chems. I did get a 75 tank on the pearl grey colour so I can at least get a match for the painter. This one is clean inside although the outside will need some attention.

I now have the head off but it seems that they used some super glue for the base gasket. I have all the bolts out including the one base nut. I have heated the base and have destoyed one length of 2x4 pounding on the cylinder with no movement whatsoever.
Any other suggestions?
Thanks Dave

[karl pa]

You should search cylinder puller. Moisture gets into the cylinder studs and corrodes them fast to the cylinder.

[kawonda750]

It has been over a week with Liquid Wrench down the cylinder stud holes and pounding with a mini sledge and 2x4 with not a budge of the cylinders. it seemed less expensive so I have ordered another cylinder head and will use it as a puller. The 1/2 inch steel plate seems like too big an ordeal.

I guess we;ll see how well it works. Now to go and buy bolts and nuts to complete the puller.... So far, it has been a new and yet, PITA experience. Never had this happen before.

[kawonda750]

I was quite skeptical but the puller worked like a charm.



After 63000 miles, the cylinders are just barely over standard bore specs. Very impressive.

[kawonda750]

I am beginning to believe that this is the first time this engine has ever beed dismantled. Every bolt and case screw is tight and require my impact screwdriver to loosen. Itliterally took 2 days to get the 10 screws out of the left case. heating many times and using the impact driver. It's a good thing I am so stubborn.....

[kawonda750]

It was a rough time. Every screw was a challenge to get loose and the cases took forever to finally split apart but it is done. I will send the crank out to be done and get new 0.5 mm pistons. In the meantime there is a bunch of cleaning to do. I think I will have the cases vapour blasted to clean them up.
Presentation is everything or, so they say...

[kawonda750]

I got a crankshaft kit with all seals and bearings delivered today just in time to get the whole thing to the crank rebuilder. The small end bearings are much bigger. My wrist pins are approx. 18 mm OD. These bearings are way too big with an ID of about 24 mm. What have they given me ??

I believe that I have answered my own question. Are these the big end rod bearings ?

[jabcb]

Apparently Suzuki used the ID as part of the part #.
wrist pin bearing: 09263-18021
big end bearing: 09263-24026

[kawonda750]

So all I can do right now is hurry up and wait. Canada Post is on strike so no mail is coming. Somewhere at the bottom of a pile are new pistons, gaskets and caliper kits along with starter clutch rollers. The cases have been dropped off at a friend's to be vapour blasted as I couldn't find anyone close enough by to do dry ice blasting. The crank is out at the rebuilder's and it could be a while although he said he should have it ready within a month. I did drop it off I think 3 weeks ago so again, who knows.

[kawonda750]

The post office has been legislated back to work so at least there is a hope that some of my parts will arrive soon. Looking forward to getting a move on with this bike. Who knows how long it will take for the backload to be cleared.

An agreement must be hammered out by May 22 or they will walk out again. I should have the bike done by that time however....

[kawonda750]

Finally some progress. I have the crankshaft back and just got word that my friend has worked on New years Day to vapour blast my engine parts. I will pick them up on Friday and the bottom end can be assembled. I have the new pistons so can drop them and the cylinders for boring next week when the machine shop is back.

[kawonda750]

Well, another in the long line of little things going wrong and holding up progress. I am now missing a crank bearing locator pin so again at a temporary standstill. I have searched the floor and evrywhere that I had the case to no avail. I have ordered another one and paid steep shipping price for this little piece.

At least I was able to install the caliper rebuild kits so the day was not a complete waste.