Item #1 in the above drawing gets a nod from me.
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C
Crank
Guest
Pretty much read through this entire thread, nice job so far and can't wait to see the final result!
F
Flyboy
Guest
Thanks Crank.
Not much to update today, weather has been miserable and raining the last two days, so i never managed to get any paint down, like I had hoped, due to the high humidity and cold temps.
So I have kept myself occupied with menial, mind numbing tasks that need to be done, you know the ones.
Got the fairing sanded and readt for primer, stripped and did more prep work on the tail piece, should be ready for paint now.
Also spent some time measuring piston ring end gaps and free end gaps, also measuring ring to groove clearences, just to make 100% sure I don't get a nasty surprise with a ring binding up on me after start up.
I am happy to report, all is well and withing factory spec.
Also spent some time cleaning gasket surfaces so I can drop the jugs and the head back on as soon as I have hung the pistons back on the con rods.
God, I hate cleaning gasket surfaces.
Lets hope the weather clears while we still have a day or two before it is back to the salt mine....while it's still open.
Not much to update today, weather has been miserable and raining the last two days, so i never managed to get any paint down, like I had hoped, due to the high humidity and cold temps.
So I have kept myself occupied with menial, mind numbing tasks that need to be done, you know the ones.
Got the fairing sanded and readt for primer, stripped and did more prep work on the tail piece, should be ready for paint now.
Also spent some time measuring piston ring end gaps and free end gaps, also measuring ring to groove clearences, just to make 100% sure I don't get a nasty surprise with a ring binding up on me after start up.
I am happy to report, all is well and withing factory spec.
Also spent some time cleaning gasket surfaces so I can drop the jugs and the head back on as soon as I have hung the pistons back on the con rods.
God, I hate cleaning gasket surfaces.
Lets hope the weather clears while we still have a day or two before it is back to the salt mine....while it's still open.
F
Flyboy
Guest
Got quite a bit done today, thanks to the break in the rain and the warm temps, meant I could get some paint down......yaaaaaay.
Finished prepping the gasket surfaces to drop the cylinders back on, GS series are notorious for base gasket leaks, so any short cut here will turn around to bite you in the bum.
Note to self; Don't be a chop and forget the cylinder O-Rings or the teardrop shaped O-Rings or timing tunnel O-Ring.
As I said, finally got some colour onto the tail piece and fairing
And did a final wet sand with 1500 grit, 2000 grit and polish on the side covers, they came out ok I guess, considering, so I am calling them done.
That's all for now.
Will see how muh work I can get done on he motor tomorrow and Wednesday.
Finished prepping the gasket surfaces to drop the cylinders back on, GS series are notorious for base gasket leaks, so any short cut here will turn around to bite you in the bum.
Note to self; Don't be a chop and forget the cylinder O-Rings or the teardrop shaped O-Rings or timing tunnel O-Ring.
As I said, finally got some colour onto the tail piece and fairing
And did a final wet sand with 1500 grit, 2000 grit and polish on the side covers, they came out ok I guess, considering, so I am calling them done.
That's all for now.
Will see how muh work I can get done on he motor tomorrow and Wednesday.
nvr2old
Forum Sage
Think back to the days you were having problems with the stripes and how disappointing all that was, now look at your parts again. They look really nice, Flyboy. You should feel very proud of yourself. Sticking to the task and getting it finished should feel really good. Nicely done. 
F
Flyboy
Guest
Many thanks Larry, thanks to your knowledgeable advice and tips.
Yes I remember the lifting pin striping and how dejected I was, having to sand it all back down, thought I would never be able to lay paint, but your work is an inspiration.
Yes I remember the lifting pin striping and how dejected I was, having to sand it all back down, thought I would never be able to lay paint, but your work is an inspiration.
B
bbjumper
Guest
+1 on the cylinder O-rings, I know it's not obvious but those skinny O-rings are responsible for keeping the oil from creeping up between the steel liners and the surrounding aluminum causing leaks.
Cheers
Cheers
G
Guest
Guest
Nice.
Too bad about the guy with the camera.......
Hey I know that guy.
Daniel
Why? It's warm where he lives...
F
Flyboy
Guest
Today was spent doing menial peasant work, you know the kind, mind numbing repetitive stuff, but is importandt and needs to be done all the same.
More specifically removing years of grunge from the motor so i can lay some paint on it as soon as I have buttoned it up again.
I have never seen so much mud, oil, and general grime in one place in my life.
But a can of petrol, a long bristle brass brush and a few hours later, i think I can confidently declare it a "relatively" grunge free zone.
The plan is to load it into Swambo's grocery getter on Sat morning and take it down to the car wash for a good steam clean with lots of hot water and steam and chemicals that will throw the green peace aunties into a tizz.
I am in two minds as to what to do with the paint, the heat proof engine paint is a little too light and silvery for my liking, fine for the barrels and head but may be a bit bright for the casings.
Standard from the factory Suzuki only painted the top casing, the bottom casing was never painted, so I might be tempted to just buff up the bottom casing with some fine steel wool and just paint the top casing, or might do both if the bottom does not clean up to my satisfaction.
We definitely know which is easier, but I also know how OCD I can get when it comes to attention to detail.
Will have to see.
More specifically removing years of grunge from the motor so i can lay some paint on it as soon as I have buttoned it up again.
I have never seen so much mud, oil, and general grime in one place in my life.
But a can of petrol, a long bristle brass brush and a few hours later, i think I can confidently declare it a "relatively" grunge free zone.
The plan is to load it into Swambo's grocery getter on Sat morning and take it down to the car wash for a good steam clean with lots of hot water and steam and chemicals that will throw the green peace aunties into a tizz.
I am in two minds as to what to do with the paint, the heat proof engine paint is a little too light and silvery for my liking, fine for the barrels and head but may be a bit bright for the casings.
Standard from the factory Suzuki only painted the top casing, the bottom casing was never painted, so I might be tempted to just buff up the bottom casing with some fine steel wool and just paint the top casing, or might do both if the bottom does not clean up to my satisfaction.
We definitely know which is easier, but I also know how OCD I can get when it comes to attention to detail.
Will have to see.
H
harley10
Guest
Very nice work on paint , you should be proud I could not do that , this whole thread is interesting ,and I thank you just for that, Brian
F
Flyboy
Guest
Thanks for the kind words Brian, keeps me honest.
Nah, don't short change yourself, with enough time, dedication and mentoring anyone can, hell if I can......
We are fortunate to have top guys on this forum who are more than eager to share their knowledge and know ho., I could hardly lay down a half decent rattle can job not too long ago.
Nah, don't short change yourself, with enough time, dedication and mentoring anyone can, hell if I can......
We are fortunate to have top guys on this forum who are more than eager to share their knowledge and know ho., I could hardly lay down a half decent rattle can job not too long ago.
F
Flyboy
Guest
Larry, you are 100% correct, but I just think the heat resistant engine enamel I get here is a little tto silver, it could be toned down by one or two shades.
Unfortunately VHT is import here and goes for stupid money, so that ain't going to happen.
I think i will tackle the lower case and see how it comes out, if I am not happy, I will paint it, I have to paint the top case as the clear coat from the factory has yellowed in places.
Unfortunately VHT is import here and goes for stupid money, so that ain't going to happen.
I think i will tackle the lower case and see how it comes out, if I am not happy, I will paint it, I have to paint the top case as the clear coat from the factory has yellowed in places.
F
Flyboy
Guest
Anyway, to day, was a total waste of a day, 32 degrees and a garage with a corrugated iron roof, you can only imagine, and bugger all to show for it.
Loaded the motor up this morning, took it down and had it steam cleaned.
Stopped and bought two cans of high heat paint for the motor on the way back and a bottle of paraffin to hone with.
Plan was to get the pistons hung, barrels and head dropped on and torqued down and the cams in.
Then finish putting colour down on the tail piece and fairing apply decals get first coats of clear down, so they can cure this week, ready for wet sand next weekend.
That was the plan.....
Fitted the rings and got the pistons hung on the nice clean motor.
Honed the barrels
Dropped the barrels
Yes I remembered the cylinder O-Rings and tear drop O-Rings.
And then...........
Oil control scraper ring
FAAAAAARKKKKK
Went inside to drink beer.
Loaded the motor up this morning, took it down and had it steam cleaned.
Stopped and bought two cans of high heat paint for the motor on the way back and a bottle of paraffin to hone with.
Plan was to get the pistons hung, barrels and head dropped on and torqued down and the cams in.
Then finish putting colour down on the tail piece and fairing apply decals get first coats of clear down, so they can cure this week, ready for wet sand next weekend.
That was the plan.....
Fitted the rings and got the pistons hung on the nice clean motor.
Honed the barrels
Dropped the barrels
Yes I remembered the cylinder O-Rings and tear drop O-Rings.
And then...........
Oil control scraper ring
FAAAAAARKKKKK
Went inside to drink beer.
B
bbjumper
Guest
I'm laughing only because I did that too.:lol: Worst part about that is waiting for another set of rings for that cyl. Look at it this way, you caught it before it was on the bike.
Get a buddy to help, another set of hands, as long as they know what you need them to do, is really helpful. I did my 850 about 5k ago and would ride mine anywhere, anytime. It's great to have that kind of confidence in your ride, and that comes from knowing you did the work correctly.
Your close...:dancing:
Get a buddy to help, another set of hands, as long as they know what you need them to do, is really helpful. I did my 850 about 5k ago and would ride mine anywhere, anytime. It's great to have that kind of confidence in your ride, and that comes from knowing you did the work correctly.
Your close...:dancing:
Chris, I use popsicle sticks to depress any errant rings as I'm lowering the barrels.
Stan, have you shipped my set of rings? If not, use the wiper from those. I have plenty of good used sets lying around that I can rob one from.
Stan, have you shipped my set of rings? If not, use the wiper from those. I have plenty of good used sets lying around that I can rob one from.
Piece of appropriate ID thin walled PVC pipe and a zip tie makes cheap and easy ring compressors. Take a little section out of the PVC rings you cut and the ties will squeeze it in and whalla....rings compressor kit.
I have seen guys use soup cans, spray paint cans sliced up..just about anything will actually work for compressing them. Get creative and stay cheap is the key.
I have seen guys use soup cans, spray paint cans sliced up..just about anything will actually work for compressing them. Get creative and stay cheap is the key.
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F
Flyboy
Guest
Many thanks Dale, but I will use one of the scraper rings that came out, they are all still within factory spec, so no biggie, just really got me down.
Not knowing what is happening in my life in the near future dos not help either.
Phhhaaa, it can stand now until I know what is going to happen.
Not knowing what is happening in my life in the near future dos not help either.
Phhhaaa, it can stand now until I know what is going to happen.
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