Finished putting motor back together...

[Pigthang]

Thanks to all of you that helped me out with those missing pieces a few threads back haha, but now I have an even bigger problem.

From the gasket kit I bought It seams almost every single gasket in the pack FAILED and I became a smoking oil spewing ticking time bomb on the maiden voyage today.

The upside, IT RUNS LOL :-k

Here are some pictures for you guys... Yes I know, it's ugly I bought the thing as a bunch of parts so I made do with what I had.

 

[tkent02]

I'm guessing you didn't use the OEM Suzuki gaskets?


Clean it up, see which exactly are leaking and which aren't, go from there.

Did you paint the gas tank yourself?

 

[Pigthang]

My friend did it, cost me $100 and he is practicing haha. and literally every gasket on the bike is leaking. Not even joking. I put it up on craigslist for $1200 i have $1500 and don't want to invest anymore into it

and they were the OEM gaskets thats why im puzzled. Everything was torqued down to the manual's specs too.

 

[tatu]

Wow! thats a serious amount of oil, that amount looks like its pumping from pressure were all the O'rings replaced in the head?

 

[Seana23]

Hi babes.
Hmmm... This sounds very wrong...
*Maybe he replaced the gaskets but didnt clean all the old bits off the face.ov the metal first... D'oh!
*Maybe he didnt fit the cylinder block stud orings... Double D'oh!!
*Maybe he set the torque wrench right... Triple D'oh!!!
You paid for this?
..... ****Quadruple D'oh!!!!
Id take it back and get him to "practice" til he gets it right!

I think you probably could have.done better yourself...

Good luck.
Xxx

 

[GateKeeper]

Hi babes.
Hmmm... This sounds very wrong...
*Maybe he replaced the gaskets but didnt clean all the old bits off the face.ov the metal first... D'oh!
*Maybe he didnt fit the cylinder block stud orings... Double D'oh!!
*Maybe he set the torque wrench right... Triple D'oh!!!
You paid for this?
..... ****Quadruple D'oh!!!!
Id take it back and get him to "practice" til he gets it right!

I think you probably could have.done better yourself...

Good luck.
Xxx

you are talking about the tank and it's paint job right.....his friend did that

I kinda like it....actually

the gasket work seems the OP did that on his own.....

 

[Roger P.]

I'm betting on a crankcase ventilation problem.

 

[tkent02]

I'm betting on a crankcase ventilation problem.

Yes, that does sound likely. For all of the gaskets to leak there must be pressure in there.

To the OP, what have you done with the breather system?

 

[Pigthang]

The motor reassembly was done myself, yes I'm learning. I've done top ends and all but never a bottom end tear down. There were no o-rings in the pack except for the gear position sensor and the oil dip stick.

I removed all old gaskets and cleaned the old surfaces before mating and torquing. I followed all the FSM torque specs and everything.

Ebay isn't really a good source for the gasket kit... where do you guys get them?

All labor was done by me. The only thing I've payed for is parts and getting the gas tank painted.

I'm thinking crank case breathing problem or... the oil seems to be separating like there is water in it. It was sitting in my garage for a while maybe it absorbed humidity from the Florida air?

These two things make sense of why ALL gaskets failed at the same time once the bike warmed up. If the water cause it im lucky it blew the gaskets and didn't crack anything...

The crank breather out the top of the motor has been unmodified. the only difference was that it was not connected to the airbox at the time of detonation.

 

[tkent02]

The crank breather out the top of the motor has been unmodified. the only difference was that it was not connected to the airbox at the time of detonation.

Any chance the air hole in the breather gasket wasn't punched out properly?
Maybe the hose is kinked or blocked?

 

[Roger P.]

The breather cover gasket is easy to put in backwards.

 

[tatu]

you could get some idea of crankcase pressure by taking off the oil filler and feeling with your hand over the hole.

 

[tkent02]

There shouldn't really be any pressure, just pulses...

 

[Pigthang]

well, i have it on the workbench on it's way down to splitting the case again and re-sealing it. Just searching the internet for a few gaskets/orings.

Any recommendations to make sure it goes together fine this time?

 

[tkent02]

Did you check the breather stuff?

 

[JEEPRUSTY]

Crikey why not check the breather stuff first?

 

[Pigthang]

The breather wasn't clogged at all. When I blew into it the air was free-flowing, plus everything needs to be resealed it literally blew all the gaskets.

 

[Roger P.]

Does the inside of the engine smell like gasoline? You said the oil was separating out. Maybe a leaky petcock? Was it overfilled with oil?

 

[tkent02]

The breather wasn't clogged at all. When I blew into it the air was free-flowing, plus everything needs to be resealed it literally blew all the gaskets.

There should not be any pressure in there to blow anything.

Gaskets like these are not meant to withstand any pressure at all.

 

[Pigthang]

its a good thing i took it down anyways. The cylinders got a nice glaze on them during the test run i think one of the oil passages may have been clogged up pretty good. I ordered new valve seals, piston rings and an oil filter.

I really kinda like this bike even though it's old and small haha. I was planning on selling it to begin with which is why I didn't want to invest money into it but for $150 more i can replace everything in the motor and have a really good running bike... and since the frame is basically empty I may paint the frame and swing arm while its apart.

Does the inside of the engine smell like gasoline? You said the oil was separating out. Maybe a leaky petcock? Was it overfilled with oil?

The petcock is literally brand new and is working flawlessly otherwise i wouldnt be able to store the tank on a shelf like it is now.