GR650 Tempter help needed

[Big Rich]

Sorry Super, I just saw this thread. And aside from what's already been mentioned, I'm at a loss as well.

I may have missed it, but are you sure it's coming from the bottom end? Maybe it could be the starter clutch jumping in and out? Obviously just guessing........

 

[Guest]

There is another member on the forum with loud metallic knocking form his GR

His looks like it is spitting out a shim
Do you have to OEM manual for the bike?
I found one but its is french.

Unfortunately he's trying to squeeze a rod bearing out one piece at a time
I hope its not that.

Here's the manual, I asked earlier on and got it, hope it still works, I had to try a few times.

Would be a nice addition to bascliff's

http://gr650.messageboard.nl/forum/viewtopic.php?t=831

 

[old_skool]

You can download my manual here without all the install crap--->http://www.4shared.com/office/uhx2-k-B/Suzuki_GR650X_Service_Manual.html?refurl=d1url

 

[Guest]

Jeeprusty..yes, I saw his thread about the shim. I do have a shop manual and was going to use it, with a little help from my friends here on GSR, to take it apart and rebuild it.

Big Rich..I don't have any experience with the starter clutch jumping in and out. I did put in a new (used) starter in the very beginning of getting this bike up and running.

I have taken the left side covers off of the bike apart, with the flywheel being taken out. All gears, starter teeth, starter pinion look just fine, no damaged teeth or marks of abnormal wear. What would the symptoms be if it is the starter clutch jumping in and out? How could I check if this might be the problem? Put it back together but leave case off and hit the starter a few times? And if this is the problem, what would I do to fix it? Any help would be appreciated.

Of course the only downside of taking the engine apart would be finding out it's not the engine but something simple. Then I've spent a lot of time and money doing something that was unnecessary.

Thanks to everyone who's offered their opinions...it helps and I appreciate it.

 

[Big Rich]

That was just a wild guess - if it doesn't have any unusual wear, I wouldn't worry about it.

I'm wondering if the clunk sound and the loss of power are really related? Have you checked that the timing chain is set properly?

 

[Guest]

Big Rich...that was my next question. If the timing chain has jumped a tooth or is off, would it still start up and idle fine but then cause issues after the engine gets revved up going down the street under load?

 

[Big Rich]

I'm not entirely sure, I've never personally experienced a timing chain jump. But it would be easy to check before pulling the motor apart.

 

[Guest]

Yep..you're right. Pull the valve cover off and take a look. I think I'll try to do that this weekend. Thanks

 

[Big Rich]

Hey Super, I just read your son is on DTT. Is his name William (Bill)? I think I shipped a muffler to you guys for somebody else about a year ago.........

 

[Guest]

Yep...that's my boy! He's working on a Tempter too. But it's kind of gone to the wayside right now. He's done a great job on it but he's got a bad oil pan.

The PO had some kind of plumbing/rubber gasket/ screw thing for the oil plug and when we got it off we found that the oil pan has a small crack in it right where the oil plug screws into the pan. And the threads are stripped. The PO probably over tightened the plug so we're looking for one. If you hear of one or a Tempter parts bike...let us know. Thanks

 

[Guest]

Quick update: And another adventure in the Tempter saga. After pulling the head off the engine, we dicovered that the left connecting rod, where the knock was coming from, seemed to have a some play in it. A lot more than the right side. So that lead me to go ahead and start taking the engine apart.

All was going well until I get to the last bolt left before I could crack open the engine cases. You know the ones? There's 2 of them that sit inside 2 little tubes, and they're allen head bolts. Yep...I stripped the last one!!

So I tried to weld a bit to it so we could get enough purchase to turn her. Didn't work and it left some metal slag on the offending bolt head. I was able to chisel off most of the excess metal and am now going to try and drill out enough to try and use an extractor.

I will say though that taking an engine apart is quite a lot of fun. It really opens up your mind to be able to see all the parts, where they are and how they all go together to make the engine go. And it was going so well...Any way, I will update later. And of course any insights would be greatly appreciated.

 

[oldrookie]

No insights for you, but good luck with it. Sure hope you like riding it after all the problems it has given you!

 

[Guest]

Well your this far and your going to replace the bolt,,, just drill it off.

Usually I start with these two and use an electric impact gun to pop them off.

 

[Guest]

Hey Mekanix...in hind sight, I would do the same. Impact them off first and go from there. But this is my first time doing this so it's a learning curve kind of thing. And to be honest, I'm actually happy I've gotten this far with only stripping one bolt!! I didn't even see these bolts at first. They're hard to see in the black and white shop manual photos.

I'm going to take my time and drill this out. I've drilled out stripped bolts before. Never a fun thing but do-able if you're patient and careful.

Oldrookie...I'm sure I'm going to REALLY enjoy this bike once she's up and running. Especially so if I get her all back together!!

Thanks everyone and keep any engine rebuilding advise coming in.

 

[oldrookie]

Some inspiration...haven't had to tear into anything for at least two weeks.

Shot of the GR in the wild.

 

[Guest]

Great pic oldrookie. I am inspired and bummed at the same time. I have the cast wheels though but other than that, the same bike. Still trudging away but I may have to take it to a machine shop. Having trouble getting a bit to "bite", if you know what I mean. But will update when there's any progress.

 

[oldrookie]

Sometimes there is no substitute for a good machine shop. Can get done in a few minutes what might take hours, or days, of frustration to accomplish on your own.

I think I'd do it rather than risk further damage to the bike or motivation

 

[Guest]

Hi Bill, I'm with oldrookie, either a large drill press or vertical mill would really make quick work of the offending bolt with little risk of any damage. Good luck with it, Ray

 

[Guest]

Thanks oldrookie and ghostgs1. I have a drill press (table top model) but don't see any way that I can fit it underneath with enough room to do the job. I did buy a few different drill bits yesterday and will try that first. Who knows?...maybe the Suzuki Gods will have pity on me and one will work. Will update later.

 

[Guest]

What are these bolts made of?