SH2: The Rebuild (Image Heavy)

[andrewsmith]

Originally Posted by _Stretchie_

Urrrgh, the love child....

Haha could be worse

Could end up with SH doing (No offence meant B!!)...

http://forums.sv650.org/showpost.php...&postcount=456

[dizzyblonde]

Meh, that cans not loud, it'll do an MOT....well up ere at least

Looking to see how long it is before its safe to say its fixed

Stretchie...Chez...I love you both. "Stop...go back" *SILENCE*.......Mwhahahahahahah!

[squirrel_hunter]

Part 14; Testing, Testing:

Well after some issues with the brakes and a week waiting for some parts, today was the big day. Test day. And I am pleased to say its passed.

The engine has more vibrations in it then before and it does sound more grumbly even with the sewing machine exhaust on it that was required for the test. But grumbly in a good way and the vibrations have settled a little now. Other than that the clutch is a little heaver due to the springs that are in there, but I should get used to that shortly. Just writing this waiting for the bike to cool down enough to change the exhaust back to my proper one and then do a fluid change as I've clocked up the first 100 miles. Will do another oil and filter at 500 before returning to a standard schedule...

[squirrel_hunter]

Part 15; Wot I Learned:

Thought I would just add some final thoughts on the rebuild in case anyone else is about to undertake one or similar...

• Make sure the engine cases are cleaned properly before taking the engine apart as its easier to stop dirt getting into places you don't want it then to clean it off once its there.
• Ensure you do not misplace the crankshaft thrust washer.
• Cheap foldable plastic crates are not strong enough to take the weight of an engine.
• Don't leave it a year between dismantling and assembling.
• Take lots of photos and label parts. However using latex gloves to keep the bits in as you take them off might seam like a good idea at the time but if you leave them like that for a year they disintegrate and leave a sticky mess.
• Suzuki do a complete gasket set. This would be better than ordering each item individually. Also make a list of the parts that you need to replace as you take them off, that way you don't forget to order something important.
• Having someone to help can be useful on occasions. Thanks to Stretchie and Grunty.

Oh and a final bit of advice... Oil is cheaper than a rebuild.

nice one, you do get used to the vibes

ohh and gaskets are a lot cheaper from the states

[yorkie_chris]

Wemoto do a gasket kit, has all valve seals and job lot. However it is worth using OE head gaskets.

[squirrel_hunter]

Part 15; Déjà Vu:

Well I have covered probably around 1500 miles since the rebuild, oil changes at 100 miles and 500 miles. Things were going good. Until yesterday. After riding to Abergavenny and spending the afternoon borrowing Ducati's when I got back on to my bike and got stuck into the twistys I thought I could feel a little vibration through the pegs and a slightly different exhaust note. BaP couldn't hear a difference and I just put it down to riding other bikes, and maybe I needed to adjust the chain or something, and maybe it was just in my head.

But no. Just made it over the bridge back to civilization when there was a bit of a bang, a massive rumble, and a catastrophic loss of power. Clutch in, and coast to a rest on the hard shoulder. For the next hour until the RAC flatbed arrived this was my view:



So the big end is gone again. I checked the oil level before I left, when I got back, this evening with the help of an assistant, and even they checked it. Every time I see the same the oil level resting aroundabout half way between the upper and lower marks. So it has oil. Its not because I didn't fill it up.

So ideas please as to what has happened here. I have a couple of ideas but I'd like to hear what the org has to say on the subject. Once my housing situation is resolved the rebuild will begin again.

ffs-unreal mate bad luck-is the issue maybe the actual lump itself as in there's a terminal inbuilt fault causing this??

[yorkie_chris]

Incorrect big end clearance used? Insufficient oil pressure? Oil pump damaged by previous crap going through it? Bearings not hard enough for job?

If they've picked up and spun bearings then it will be hard to tell issue due to general carnage masking source of problem.


This is why I will not get reground the 2 paperweights I have due to 99 engines blowing big ends.