Enfield's Rebuild

[EvilEnfield]

There are very few holes under the crank shaft for it to fall out of, I think I'm going to save up for a gasket set and exhaust cam shaft, have the engine apart and paint it. I can't believe I was so close to riding a couple of months ago and now I'm done in by a bolt. Never mind, these Cornish hills should be a giggle come winter, might trade it in for a Ural Gear Up.

 

[EvilEnfield]

My gasket set has arrived, woo hoo, but I've been reading the manual (for an 8 valve, I haven't got a real one) it says I need a special tool for taking out the 8mm head bolts, is that true or will an 8mm deep 1/2" drive socket be ok? I don't want to start and then be stuck for tools. Are they really 8mm or is it a typo? Tiniest head bolts ever.

 

[hampshirehog]

If you don't have the special tool all your children will be born of the devil and your hair will fall out........

No special tools required. The Suzuki manual is available on Cliff's site for free if you haven't got it yet. You'll just need a torque wrench when you put the cylinder head back on.

 

[EvilEnfield]

Cheers HH, I'm afraid you're correct about my children. Which manual is it on Cliffs site, I downloaded the one I thought it was and it was different, unless I clicked the wrong one, I'll have another look actually.

 

[SVSooke]

http://www.mtsac.edu/~cliff/storage/gs/GS750_16valve.pdf This is the one you need.That list can be a little much,missed the one I needed for mine to.Asked here and had my nose nicely pointed to it.

 

[EvilEnfield]

Thanks for the link, I thought that was the one I downloaded, must have clicked the wrong one.

Anyway, I've got the head and block off, but I heard that bolt fall as I lifted the block away. I'm sure it's sat in the bottom somewhere now but I still can't get at it, so, my new question is- can I split the case without removing the pistons, governor and clutch etc? I think if I could then I would probably be able to just lift the top a bit to be able to get a magnet stick in there. I hope so.

 

[hampshirehog]

You can leave the pistons on but you have to pull the clutch off. I don't know what you mean by the governor.

Is the engine out of the frame now? If it is that bolt will come out of the sump with a bit of a shake.

 

[EvilEnfield]

I was trying to leave it in the frame, I don't know why, trying to back track as little as possible I suppose, but it's nearly out now, I think this was just one big act of Suzuki God to make me clean and paint that damn engine, would probably never have happened if I'd just done that in the first place. Curse my laziness.

 

[EvilEnfield]

Bolt is out, arms and shoulders are killing me, engine is being de-greased ready for painting, can't find my piston ring compressor, but I only have one anyway, or adequately sized hose clips. Anyone have any back yard tips for getting the pistons in without any proper tools?

 

[EvilEnfield]

Few pics here-


Image0521[1] by EvilEnfield, on Flickr


Image0519[1] by EvilEnfield, on Flickr


Image0518[1] by EvilEnfield, on Flickr

I'm going to order some ring compressors, too many cylinders to mess about with fingers.

I found this on the floor, I'm assuming it is from when I was shaking the engine about or when I removed it, but hopefully it's just from my car.

Does anyone know what this is?


Image0527[1] by EvilEnfield, on Flickr

I really do need a better camera.

 

[hampshirehog]

That little bit isn't not off your car (unless that's got a Suzuki engine in it). It's called a pawl roller part number 09209 - 05011.

If you look at the Alpha sports parts diagram, gear shifting tab you'll see where it goes.

You don't need ring compressors as there's a really good taper on the cylinders which makes popping the pistons / rings in easy. The key is getting things square - I use 6 inch lengths of plastic sink waste pipe under the pistons -it fits perfectly and gives a little bit of 'squidge'. However, if you don't feel comfortable doing it free-hand then use 650 Triumph Bonneville ring compressors (or BSA A65 - same things). They're cheap and easy to use and designed for bikes; they are a must on BSAs as there isn't any taper but just make things slower on a Suzuki

 

[EvilEnfield]

Thanks HH, good idea on the pipe, I'll give it a try tomorrow. Hope that little spring isn't missing behind that roller too.

 

[Nessism]

Sorry to be a bummer but that green base gasket from Athena SUCKs! I suggest you stop and get OEM Suzuki gaskets otherwise you almost certainly will get leaks and have to do the job again.

Photo below shows how the Athena base gasket extruded out of place under the cylinder clamp load of 27 ft-lbs on the head nuts. Not good.

 

[EvilEnfield]

Nessism, no worries, someone had to say it, I know I'm going to have to do it again at some point in the future, but I've only worked 13 days out of the last month and OEM is massively expensive, this set was all I could afford for now, hopefully it'll just see me through to next year and I'll do it again.

 

[EvilEnfield]

My gasket doesn't look as bad as that, I hope it's not anyway, it don't think it says Athena on it anywhere either, is Athena a well known bad make? Just had a look, mines d&k, I think I'll put some liquid gasket on the base one.

 

[Nessism]

Dude, that's what the gasket looked like AFTER if failed with only 200 miles on the clock! Green gaskets = Athena. BAD BAD BAD. The cost of a brand new OEM base gasket is only about $11

Part# 11241-45401-H17

http://www.andersonvintageparts.com/index.php?crn=12&rn=24387&action=show_detail

 

[hampshirehog]

?11.80 at Robinsons. That's what I would use.

I've only ever used DK stuff on mopeds and CG125s, that sort of thing. They're cheap for a reason.

Genuine head gasket is ?62.40 - if you want to go that way (strongly recommended) I've got a new one you can have for half price plus the p&p. Send us a pm if you're interested.

 

[EvilEnfield]

Thanks HH, I'll take you up on that offer, probably wont be for a couple of weeks though if that's alright?

 

[Nessism]

I never had problems with the Athena head gasket, it was the base gasket that failed.

 

[EvilEnfield]

Hello everyone, I'm back from my poverty holiday now, and I'm ready to get back into it.

HH thanks for that offer but I got a pair of gaskets from a bloke down the road for beer tokens so I won't need it now.

I'm going to put the stock airbox back on soon, I'm tired of farting about with the pods, especially with the horrendous wind and rain we've had here, I always have a flat spot somewhere no matter how many configurations I try, so back to stock it is although I will be trying to adapt it so that it opens up to make it easier to install and remove as necessary.

Does anyone know what are the easiest to fit rear sets?

Good news too, I got a diggerital camera for Christmas so there'll be better pictures too. Took a couple with my old Yashika before Jessops closed though, very arty -


gsx by EvilEnfield, on Flickr