Camshaft Top End Rattle

[AF_Bill]

Don, thank you for this very detailed thread. Since my 850 is making the same noise, I've been reading this everyday.
You had mentioned something about the carbs being out of sync. I took my bike to a mechanic friend and he said that it sounds like the carbs need to be rebuild and re-sync. This might fix the problem, then again it might not.

 

[Suzuki_Don]

Don, thank you for this very detailed thread. Since my 850 is making the same noise, I've been reading this everyday.
You had mentioned something about the carbs being out of sync. I took my bike to a mechanic friend and he said that it sounds like the carbs need to be rebuild and re-sync. This might fix the problem, then again it might not.

Bill, glad my thread is of use to others. Sometimes I think I am posting too many pics and sometimes I think this thread is developing from a query about a noise in my motor to a thread on an engine rebuild project. But as long as I receive encouragement from people like you I will keep going.

I should be able to start the motor in a week or two I guess. I will see what happens then, hopefully the noise will have gone away, if not then I will do a full vacuum synch on the carbs and if that has no effect then I will muck around with the points plate; advancing a bit, retarding a bit. And see what happens.

Thanks Bill for your suggestion.

 

[Guest]

Bill, glad my thread is of use to others. Sometimes I think I am posting too many pics and sometimes I think this thread is developing from a query about a noise in my motor to a thread on an engine rebuild project.

Not at all Don. I've been following this one too - feel your pain - even though I haven't posted. Looking forward to you getting it back on the road. Love all the pics.

 

[Suzuki_Don]

Question on Springs in Clutch Hub Driven Gear

Question on Springs in Clutch Hub Driven Gear

In the back of my clutch hub I have six springs, 3 are heavy duty and the other 3 are light duty (thinner wire). How much play or movement should there be allowable in these springs. I can rotate 2 of the large springs back and forth a small amount (about 1/16th") and there is slight end play on the springs, in other words they can be pushed back and forth a small amount along there length. Also two of the smaller springs have the same symptoms.

How much play, if any, should there be in these springs. And could they be causing the noise in my motor at idle. If so what is the remedy?

This part is no longer available new from Suzuki and I imagine if it was it would be horrifically expensive. My clutch hub has a straight cut gear on it.
If this is a problem how do you get the springs out and where do you obtain new springs to go back in before it is welded up again. What about new rivets, are the old rivets long enough to reweld.

I will post a video tonight of the amount of play in the springs.

Thanks again for any help.


http://s226.photobucket.com/albums/...ine Rebuild/?action=view&current=P1000976.mp4http://s226.photobucket.com/albums/dd105/donclifton/GSR PICS3/?action=view&current=P1000976.mp4


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[tkent02]

Here ya go. Those springs shouldn't have any play.
This should work well enough to see if the springs are causing your noise.

http://members.dslextreme.com/users/storagecliff/images/quick_clutch_rattle_repair_by_tkent02.pdf

 

[Nessism]

Here is another solution... http://www.theflyingbanana.com/clutchhub.htm

The amount of looseness in that clutch hub is typical, and shouldn't make as much noise as this bike was experiencing. That said, it would be a good idea to eliminate that extra play.

 

[Suzuki_Don]

Here ya go. Those springs shouldn't have any play.
This should work well enough to see if the springs are causing your noise.

http://members.dslextreme.com/users/storagecliff/images/quick_clutch_rattle_repair_by_tkent02.pdf

Thanks Tom, I had seen this somewhere in the far distant past, but had forgotten where to find it. Thanks for the link. I might do this quick and easy mod and see how it goes and if the noise comes back then it's not a biggie to pull the clutch again. Thanks.

 

[Suzuki_Don]

Here is another solution... http://www.theflyingbanana.com/clutchhub.htm

The amount of looseness in that clutch hub is typical, and shouldn't make as much noise as this bike was experiencing. That said, it would be a good idea to eliminate that extra play.

Thanks Ed, you've come through for me again. I will try Tom's quick remedy first and then do the other mod later on of inserting the washers against the end of the springs, but will need to separate the hub halves to do it. A job for another day.

 

[Suzuki_Don]

Not Long Now -- Nearly Ready to Start

Not Long Now -- Nearly Ready to Start

Almost done -- Should be able to start her on the weekend.

Just one more task to go. Fit the headers and silencer.

Keeping fingers crossed for a silent motor.

Since last time I posted I have fitted the generator cover, connected the wiring up, starter motor, clutch, carbs, coils, etc. Filled motor with oil, and spun it with car battery so oil light goes off. Removed valve cover because I forgot to oil the shims and valve gear and put moly on the cam lobes. So just headers to go and then hit the starter.


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[Nessism]

What's going on with your engine Don? Had a chance to fire that bad boy up yet?

 

[Suzuki_Don]

Yes Ed, I started it on Friday night, but only ran it for 2mins, as Motoman says not to idle a new motor or free rev it in shed just to hear it. It should be run under load on the road so the rings bed in properly. Although the fact that I have already put 100 miles on these ring,s then the window of opportunity may have already passed. Anyway I want to do the best thing for my motor that I can.

I am currently working on my freshly painted fuel tank, as I cant run the bike on the road without a tank on the bike. Should get it on today.

BTW when I started the bike for the 2mins, there was some popping from the exhaust as I was revving it. Could this be too lean on the pilot circuit. I did replace the 150 pilot air jets with 175s while the carbs were off. Remembering these carbs came off a 650G which had 160 air jets as standard and the 650E had 175 air jets as standard. That's why I made the swap and the fact that it was really rich the first time round (original rebuild).

Thoughts please?

 

[salty_monk]

Popping on the exhaust could be due to impurities in the exhaust, engine from cleaners etc....

I would get it out on the road & run it or adjust the pilot screws out a bit to compensate then go run it.... (that's me though!)

 

[Suzuki_Don]

Popping on the exhaust could be due to impurities in the exhaust, engine from cleaners etc....

I would get it out on the road & run it or adjust the pilot screws out a bit to compensate then go run it.... (that's me though!)

Thanks Dan, will do.

 

[Nessism]

Strict adherence to Motoman is folly Don. Just get the bike out on the road, run it around town, and use lot of throttle. 99% of all internal combustion engines don't follow Motoman's routine yet the rings seal up just fine.

 

[Suzuki_Don]

Strict adherence to Motoman is folly Don. Just get the bike out on the road, run it around town, and use lot of throttle. 99% of all internal combustion engines don't follow Motoman's routine yet the rings seal up just fine.

Thanks Ed. I did not see any evidence of blowby when I pulled the pistons, but maybe 100 miles was not enough to stain the pistons even if there was blowby. I did run the motor fairly hard for those 100 miles. I tried to keep it under power most of the time, if not doing that then I was decellerating.

Project finished, unless the motor gives me more problems. I fitted all the paintwork today and now we have rain predicted for the next week. Can you believe they have just declared the seven year drought is over/finished. Don't know when I will get to ride it now.

A few pics for your purusal. The color is not quite right, it must be my camera. The blue is not as pale as in the photos.

.

 

[Guest]

That's lookin' real good Don!

You've done an awesome job getting it back together and looking so neat and clean. Fingers crossed your noise is gone and you get lots of enjoyment out of her.

As for the rain, I know what you mean.

When I was in Sydney last Tuesday/Wednesday the weather was great, but up here it's just come over all cloudy and rainy again the last couple of days.

Gonna be another wet spring I think...

 

[Suzuki_Don]

That's lookin' real good Don!

You've done an awesome job getting it back together and looking so neat and clean. Fingers crossed your noise is gone and you get lots of enjoyment out of her.

As for the rain, I know what you mean.

When I was in Sydney last Tuesday/Wednesday the weather was great, but up here it's just come over all cloudy and rainy again the last couple of days.

Gonna be another wet spring I think...

Thanks Pete, the new 550 badges belie to 700cc motor sitting in there.

 

[Guest]

Oooh nice! I skipped a lot of this thread coz I got totally lost with degreeing cam's and things, but didn't realised I'd missed the capacity increase!

That should certainly give it some zip

 

[Suzuki_Don]

Oooh nice! I skipped a lot of this thread coz I got totally lost with degreeing cam's and things, but didn't realised I'd missed the capacity increase!

That should certainly give it some zip

I will reply with pics for your choke issue in the morning. Off to bed now.

 

[tkent02]

Strict adherence to Motoman is folly Don.

Why do you say this? He makes more sense than anything I have ever seen written about it.