metallic tapping noise

[Nessism]

Great job on taking the engine apart to verify everything is ok. Regarding changing the crank bearings, wouldn't hurt if they are not too expensive. I trust you measured the crank journals to make sure they are not worn too much? Wouldn't hurt since you've gone this far.

Good luck.

Edit:duaneage posted while typing...
Regarding installing valve stem seals, I use a small socket to tap them down and make sure they are seated.

[Dave_17954]

gasket sets

I'm getting ready to order my parts for my rebuild. The suzuki dealer quoted me a price of $83.40 for a complete engine gasket set. This was the Vesrah gasket set. Ive noticed some opinions on these sets on different posts. I dont want to have to tear anything back apart once i get it together so what would be the absolute best gaskets to use. Is there one company that stands out more than the others with a quality set? The suzuki dealer said that Vesrah is all they use in the shop but as usual I'm a little skepitcal. I'm replacing the con-rod bearings, crank bearings ( not because they need it but because I'm in that deep) complete gasket set, valve guide seals, and also dipping the carbs and carbs rebuild kits. I get laid off the 31 of jan. so I'll have lots of time to work on it. Even machinists like myself are struggling around here with the job market. Everything has been cleaned and measured and I'm ready to start rebuilding once I get my parts.

[TheCafeKid]

According to the Zook shop manuals i have (some of which you gave me ) IF you are replacing ONE conrod bearing, they should ALL be replaced. Also, it recommends if wear is inconsistant across the four cylinders that the crank be pulled, and checked for distortion, tapering, and the runout checked. As far as gaskets, i have actually had pretty good luck with Vesrah. I have NOT had such luck with Athena, as they cut theirs a little funky, and i steer well clear of Cometic. Every Cometic ive happened to have used has leaked like a siev.

[chef1366]

I like Cometic gaskets.

[49er]

I used Vesrah on my 850 rebuild. Good quality and no leaks.

[Dave_17954]

I'm thinking if things are prepped correctly the Vesrahs would be a good way to go since thats what they use at the dealer....

[Dave_17954]

Crank Bearings Question

OK I'm down to ordering my crank bearings and have run across this issue and I dont know exactly what to do. As you can see according to the parts look up and suzuki dealer lookup is the same on the top side of the case there are 2 #5 bearings there in the middle but when i got it apart there are the #6 bearings all the way across was wondering if i should replace them the way they came out or do I put the 2 #5 bearings on the top like it shows in the diagram or does it matter? Not to worry I havent cleaned the lower side up yet. I used plastic gauge to check them and will be putting back in the "black" marked bearings the same kind as whats in it now. Thoughts?

[duaneage]

I would do it according to the diagram. the slotted bearings feed oil around the journal and the thrust appears to be in the middle pair.

[49er]

I believe that the diagram for the upper case has the numbers incorrectly recorded on the center bearings. The oil feed is coming through the gallies in the lower case, so the grooved bearing shells must be fitted on that side of the case. If the grooved bearings are also fitted on the upper case middle bearings, you will loose some oil pressure in that area.

To me, the trust is usually taken up on the clutch end of the crank. I think the double center bearings are located that way for additional crankshaft support, to offset the load exerted on it by the drive train for the cams and their tensioner.

[duaneage]

I have a factory manual, I'll see what it says

[Dave_17954]

I got my diagram from the alpha sports parts lookup website. I noticed the suzuki dealer has the same diagram on there parts lookup and they told me I needed 8 of the grooved bearings and 4 of the plain. below is 2 pix i took from my factory service manual describing the bearings. also I'm pretty confident this engine has never been apart since it left the factory and I would think that since coming from the factory they would have installed the proper bearings. I'll take my service manul to the dealer when I order and see if they have any answers on it. I agree it may be just a printing error on the diagrams but when ones this deep in a motor you want to be 100% accurate before you button it all back up.

[Dave_17954]

hello all

Well the day of good news has arrived. Got my engine completely rebuilt and all remounted back in the frame. Officially fired it up at 6pm this evening. Totally rebuilt from the cases up. $500 in parts some including crank bearings, conrod bearings, all new seals/ gaskets/ and orings, valve stem seals, piston rings, cylinder hone job, and with a special thanks to Bribird for spotting a worn 2nd gear I replaced that to. Plus a lot of cleaning and measuring done as well. Hand lapped the valves. A true learning experience all the way. Now just have too wait on my rear brake line/cylinder assembly that I'm replacing and I'll be ready for some serious riding time. Want to send out a special thanks to all the members who have given me advice. To the Cafekid I'll have to swing by this summer sometime and let you listen to a real quiet motor unlike my last visit lol. Theres just something about doing a job yourself and feeling that satisfaction when you hit the start button and have it fire right up. Had it running for approx 5-6 minutes tonight and NO NOISE. A combination of a bad conrod bearing in #4 and cylinder #4 which needed honed. I'm very much looking forward to hitting the roads with a much quieter ride this summer. Heres a pic of my finished motor with my trusty assistant.

[Nessism]

Good work. Congratulations!

[BassCliff]

Hi Mr. Dave_17954,

Impressive! I've enjoyed this thread, very educational.


Thank you for your indulgence,

BassCliff

[Dave_17954]

Thanks guys. When I get all my digital pix sorted out I'll post a link to my photobucket so others can use them for reference. I referred back to them many times during my rebuild. Or if anyone has any particular pic they would like to see of a 1981 internal gs650gl engine let me know and I can send/show I've got them all. For example heres my worn 2nd gear on the lower right which Bribird spotted after I showed him a pic of my transmisson gears one evening. When in doubt take pix as you go.. You never know when they will come in handy. And when your all done burn them to a cd and put them with your repair manual for future reference.