First Street Bike Project - with a few questions

[Flyboy]

Yes, like Daniel says, try and secure the airbox back as far as possible, what will also give you some precious millimeters is to remove the valve cover, and put it back on once the engine is back in the bike.
Daniel, I know Andre used a similiar method to get the engine back into his 1000G with good results.

 

[Guest]

Interesting. I think that might work Daniel as I removed my airbox with the engine still in the frame. Just need to borrow a second jack.

Thanks for the pointers.

Sci85

 

[Guest]

Well, I know it's been awhile since I posted any updates. I've been frantically trying to finish off the CR80 dirt bike build so I can get some funds for the 550 Katana. I made a lot of progress on that bike recently and am just waiting on the final parts to show up so I can finish the remaining pieces which is the carb mostly. Once that's back together, I can put the rear subframe back on and she's done! Here's a pic for those interested.

Anyway, I did manage to get some more teardown work completed on the baby kat finally! Got the exhaust off (not sure the maker), foot pegs and rear brake master cylinder. Thankfully no broken bolts. All the cylinders had bolts except for one which had studs. Go figure. Did these bikes come with studs from the factory? Pipe's not in too bad of shape actually. A little work with the wire brush and some buffing and I think it will come out ok.

Here are a couple shots of the exhaust valves. One thing I noticed. On one of the outside cylinders, you can see that the exhaust stem and back of the face is white while the others are carbon black. Any ideas on the cause of that? The others have a lot of carbon build up so I will probably be pulling the head and cleaning them up at the least. Any thoughts would be appreciated.

Here's the white one:

And the others:

Sci85

 

[Guest]

Well, I really got with it today. Got her almost stripped down except for the kickstand, triple tree's, shifter & footpeg mounts (how do you get these off?). Should have the engine out by the weekend whoo hoo!

So here she is at the end of today.

Ok quiz time. What's wrong with the below picture? This is the front end as I received it. I never realized it until today. Can't believe I missed this when I bought the bike. Doh! Who would do this??

I plan on having the frame blasted to prep it for paint. Do you guys remove the rider foot peg mounts or leave them on? I can't figure out how they come off though.

Lastly, if someone would be so kind as to comment on my previous post about the valves, that would be much appreciated.

Thanks and Happy New Years!

Sci85

 

[GateKeeper]

Well, I really got with it today. Got her almost stripped down except for the kickstand, triple tree's, shifter & footpeg mounts (how do you get these off?). Should have the engine out by the weekend whoo hoo!

So here she is at the end of today.


Ok quiz time. What's wrong with the below picture? This is the front end as I received it. I never realized it until today. Can't believe I missed this when I bought the bike. Doh! Who would do this??

I plan on having the frame blasted to prep it for paint. Do you guys remove the rider foot peg mounts or leave them on? I can't figure out how they come off though.


Lastly, if someone would be so kind as to comment on my previous post about the valves, that would be much appreciated.

Thanks and Happy New Years!

Sci85

Missing the cotter pin on the castle nut ? Unless there is something I cannot see

 

[brslk]

Missing the cotter pin on the castle nut ? Unless there is something I cannot see

Zip tie the speedo cable to the caliper mounting hole? (meaning someone removed and left off the caliper?)

 

[GateKeeper]

how could you miss a caliper not mounted ? I saw that but figured Sci85 did that to stop it from flopping around, until he was ready to put it back correctly...

 

[cowboyup3371]

The bolts will unscrew from the inside of those footpeg mounts.

 

[7981GS]

Remove the plastic cap and you will see the Allen head bolt:

http://www.boulevardsuzuki.com/fich...y=Motorcycles&make=SUZUKI&year=1982&fveh=2115

Daniel

 

[Guest]

Ahh, the 'ole hidden bolt trick haha. Thaks guys.

And yeah, somewhere along the line a PO decided a single front disc would be better than two and yes, I completely missed that

Funny how you can pick out the littlest things sometimes but completely miss the smoking hole in the ground!

Anyway, I'm betting they used the same calipers on many models and years so shouldn't be hard to replace?

Sci85

 

[Guest]

Btw Gatekeeper, in my defense I was unable to ride the bike when I bought it and it was dark and I can't see and I swear it was there at one point...

Sci85

 

[cowboyup3371]

I have a couple of 750 rotors that will work if you are interested (I'm swapping over to Salty_Monk's twinpot setup)

 

[Flyboy]

Nice progress there Sci, good to see things happening, as far as the valves go, my guess would be a lean condition on that cylinder, PO was probably not great into maintenance, tell by the missing brake.
No biggie as long as the valve isn't burnt, you will sort that out when you put all back together and tune her up, so don't sweat it too much.
If you are pulling the head, might a well give the valves a grind while you in there.

 

[Guest]

Thanks Flyboy. I need the encouragement. Following along your Jennifer rebuild with anticipation. I spent the better part of two days getting after it and my back said that was wayyyy too much. So after a quick powerwash of the motor, I spent the better part of today in the chair.

Cowboyup, thanks and I would be interested. Are they identical to mine? PM me what you are asking. I'm still cracking up over that missing caliper...
Here's the right side...

And thanks to all the others who have gone before me, I was able to lay the frame over on its side and simply lift it off the motor. Was a snap and much lighter than lifting that engine.

Will begin the search for a good blaster for the frame and swingarm, etc to begin the rebuilding process, Finally! Frame is in pretty good shape for a 30yr old bike and through it all there was only a single broken bolt (right side lower motor mount, in the frame). I feel very lucky.

Here's where we sit today...

And the motor. Don't know how you guys get your cases and fins clean enough for painting. This is mine after 20 min with the power washer.

Notice the single exhaust port with studs. Funny.

Will post pics of the engine top end tear down soon.

Thanks everyone for all your help.

Sci85

 

[brslk]

That is truly bizarre about those studs.
I guess this is what happens when you buy a 30 year old bike that has had lord knows how many previous owners.

What type of cleaner are you using on the motor? simple green? something stronger?

I'm not too sure how I will be cleaning mine because A: no pressure washer (I will be buying one) B: I'm not gonna pressure wash it inside the garage. C: the weather. It's a little cold and snowy to do it outside.

However I do it, I better get going! you're getting to far ahead of me.
Or maybe... just maybe that is my plan. To let you get just enough ahead of me so that I can learn from your mistakes...hmmm...

Bruce.

 

[Guest]

Hehe, that's the good thing about the GS forum. There are so many guys who have gone before us, not much is unknown and if it is, someone's always willing to help out.

To date, I haven't used any cleaner on the engine. I just loaded it into the truck (has a lift gate on it) and took her down to the local car wash bay. Didn't work too well though. I will try some simple green or something else tomorrow (searching the threads now...)It's not acting like winter in Missouri so far this year. It actually hit 62 today and will be warmer tomorrow! We also usually have snow by now. I'm trying to take advantage of the warm weather as much as I can so I too will be hitting the store in the morning and then back to the wash bay.

All this warm weather makes me itch to go ride but I don't have my license yet. Oh well, I may just sneak a little trip on my boys little electric razor Moto bike hehe.

Sci85

 

[GateKeeper]

Just pressure washing will not get you the results you guys are trying to get.....ask me I know....

you will need to scrub some for sure, you will need a good degreaser as well, I even used a wire wheel attached to the drill, a wire brush, a baby bottle brush, some good old elbow grease are in store, if you really want the 30 year old grunge off.....

my last step was to spray it down with simple green, let it sit and then hit it with the power washer, this got I think all the crap off, but all of the above needs to be done, unless you have a really clean engine to begin with.

my last step will to wash it down with some paint thinner, degreaser, or alcohol to prep it and ready it for painting, right now it's just sitting on the dolly, with a big old towel over top of it.

 

[Guest]

Thanks for the input GK. I do have some simple green but will need to get some brushes. Sonds like a lot of time and elbow grease and even then I would be worried that it's not enough. I've done enough painting to know that if the surface isn't perfect you will have issues.

Do folks have the engine blasted with something while it's all still together? Seems like that would be a quick and easy route if it's possible?

Sci85

 

[GateKeeper]

Blasting with baking soda is an option, and I thought about it, but I just put in the time and effort into the elbow grease and I can say my engine is probably clean enough now to take paint.

even a small tooth brush to get in between the fins will do a nice job of getting the gunk out, I found small brass brush's work well, you can find them in the automotive section, or check your favorite gun store, they have them as well, guys use them to clean their rifles and pistols, to get the gun powder residue off, and not damage the finish on their firearms

 

[Redneck]

I did a wet blaster on the heads of mine and it came out great I did have to run a water hose through all the pores and holes for about an hour when done to get all the media out of all the nooks and crannies. But it was mighty clean. Then it dried and I realized it was time for another hose soaking but that was it. All good after that. Much less effort if you have the means available.

Paul