Daimo B
Member
Registered: 20th Mar 00
User status: Offline
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As theres some bikers on here...
Well we started on Friday, equipped with Tea and rubber gloves, we set to work removing the old engine... It got delivered from the bodyshop all nice and shiney and clean with its new panels..
Tank, carbs, bodywork all came off without issues. We had a bit of a mare with the rear engine mount, and also removing the rear bolts holding in the exhaust at the rear block, but eventually with some perswasion, it freed.
Next was the exhaust, dammmmnnn, the thing was a mare. The clamp at the bottom that sticks out the fairing was seized solid... After about an 30 minutes of fiddling, it eventually came off..
Next up, rear wheel off and down to tyre shop (Watling Tyres, Gravesend, will plug them as they are always superb with me) to have the damn bolt removed, they also gave us some new bolts for the exhaust clamp for free. Nice :-) 10 minutes and we were on our way back home.
After putting everything in its place in the garage so not to confuse nuts and bolts, we removed the last few bolts and dropped the engine out. Getting the lump out (bar the few bolts) was relativly simple. Gettting it in, another matter....
We took the chance to give the bike a good cleanup. All the frame, all the oily gunk around the front sproket, inside the swinging arm, rear shock etc (it gets used every day, all weather), it was nasty. It left dollops of gunk on the garage floor which I walked in and treded all the way through the hallway in the hosue (got beige carpet in the living room, so gald i never walked in there!!!). Left the misis cleaning that up... :S Next up, engine back in..
Recently my dad has had a spine operation to remove two discs (inc cutting away some of his spine) so I was dam I wasn't going to let him do any lifting. We must have about 3-4 trolly jacks between us, but his was at his house, mine and my GF's were at our mums. Siccor jack simply wasn't going to work either, so wooden block lodged underneath and manpower it is then... We spent a good hour trying to get the engine in, becoming concerned as it was catching on a few bits, we couldn't work out why.. We eventaully got the rear exhaust over the frame, but we still couldn't get the front of the engine up into position. I tried liting it from thr top of the frame, sitting on the floor, and doing it myself with a full engine of oil wasn't a comfy thing to do, it jsut wouldn't go in. As it happens, the engine slipped down a bit by mistake, but into a position where the lower rear engine mount fitted. Blinding, get that lined up, bolt went through, the engines half in, ish...
Once the rear was in, it was a case of lifting the front of the engine up and alligning the other bolts, This saved half the weight and was so much easier. We had a few issues getting the engine alligned, but after some tightening, loosening, tightening, loosening etc etc, the engine was in and in place... Copper grease on EVERY nut and bolt we removed, so to ensure no issues should we ever need to take anything out again (why manufactures dont do this as standard defies me, tyhe original nuts were b1tches)
We re-connected the wiring up and hoses, re-connected the carbs, battery and fired up up without the tank or exhaust on. It tried to fire up, wicked, the new engine works....
By this time, it was about 10pm on Friday, the old man was starting to loose his rag at silly things, so i made him stop, he was going away for the weekend, and I thought it better to leave the bike, get some rest, come back to it on Monday with a fresh head...
Monday came and I was at work, so my dad went in to carry on working. I came home to find the bike re-attached together, fairing and tank back on, it looked spotless, cleaner than the day I picked it up orignally. The brand new exhaust was on and shiney, and it was ticking over as I pulled up.. He had started it without any major issues (other than connecting the vacuum and fuel pipe the wrong way, then removing the plugs etc until he worked out what it was ha ha), then had drained the oil, serviced, new filter etc....
The bike sounds SO quiet with a brand new exhaust on, gonna take some time to get its standard note back. Good point are that i've got my old exhaust to chop up come the time I can afford to get a rear can. The new engine sounds so tight still (done 3k per year, women rider, got all the documentation too).
Bad points...
Decided to carry on and check the rest of the bike. We removed the rear caliper It seems the rear pins in the rear caliper are seized SOLID.. £3 EACH, for a peice of steel, was not to impressed, but what can you do..... In the end, we had to drill out the exisiting pins, but its meant we've had to trim some of the pad housing (where the pin goes through), the pads are in, but one is at a slight angle, it'll be ok and brake ok, but will give un-even pad wear, so i'll be loooking for a 2nd hand Curvy SV rear caliper before winter, probably asap.
All in all, i've spent about £250, i've got an older engine, but with half the mileage of my broken engine (broken was at 21k), that includes bits and bobs, oil, filter etc... Its had a full clean and service, and looks spotless (you watch, the 1st day back to work, it'll hammer it down and get filthy again >-( ). It can then be booked for an MOT on saturday as its run out while it was away and should be good to go again. Im hoping to get out on it tonight round the block to check everythings ok and then re-check all the bolts.
Last night....
GRRRRRRRRRRRRRRR :evil: :evil: :evil: :evil:
Rear caliper went on tonight, no issues with it, but I need another caliper as the original holes where the pins are have had to be widened.
Moved to the front brakes, the SAME damn issue :evil: Pins have rounded right off, tried bolt croppers with extra pressure, nothing, they just slip. Going to need to get those gits out now, more pins please...
I really angry as i've paid a suzuki dealer to do all this for me. I have been doing basic maintenance, but the principle of paying out a lot of money at a dealer is to have it done right. I am most angry, they not done a good job on a lot of things. Will be having serious words.......
After getting the fronts back on, we bled both the front and rear brakes with new fluid. Rear wheel and hugger in, and off for a test ride...
Engines running great, took it for an easy 8 mile ride with a small bit of motorway cruising and its running perfectly. Dead chuffed.
Got home and checked all fluids, bolts etc and alls sweet as a nut (boom boom...).
Progress pics..
Stripdown part 1..
Part 2, carbs off, electrics off, oil drained (drained before went to bodyshop and refilled only a bit).
Like our makeshift non moveable jack 
Heart transplant in full swing.
Shiney panels
Engines compared (sorry for poo image, wrong camera setting..)
K1 engine is the black one, K2 (busted) is the silver blocked one..
New heart in.
Then we have a missed update day.. But...
Check me out baby
Rear hugger back on, all sorted. Ready for MOT.
Grr damn camera..
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Rob_Lee
Banned
Registered: 9th Dec 05
Location: Folkestone Drives: Nova 1.6 16v
User status: Offline
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3CorsaMeal
Member
Registered: 11th Apr 02
User status: Offline
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the orange bucket never moved 
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Rob_Lee
Banned
Registered: 9th Dec 05
Location: Folkestone Drives: Nova 1.6 16v
User status: Offline
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Does anyone know what its for???
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Rob_Lee
Banned
Registered: 9th Dec 05
Location: Folkestone Drives: Nova 1.6 16v
User status: Offline
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quote:
Originally posted by 3CorsaMeal
the orange bucket never moved
Neither did the blue oil container!
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Cybermonkey
Member
Registered: 22nd Sep 02
Location: Sydney, Australia
User status: Offline
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quote:
Originally posted by 3CorsaMeal
the orange bucket never moved
fucking camera moved while pics were taken tho 
BTW i dont understand this thread?
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Daimo B
Member
Registered: 20th Mar 00
User status: Offline
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Moneky - im seeking attention to gain my own coolness..... Rear the first line if your un-sure on the reason...
3CM - THe orange bucket was used to clean the rear hugger which was quite dirty with gunk and oil... it is a highly expensive 99p bucket from B+Q of which the handle came off about 10 minutes after we got home...
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3CorsaMeal
Member
Registered: 11th Apr 02
User status: Offline
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talking of bikes, i'm considering getting a twist and go scooter for work
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Cybermonkey
Member
Registered: 22nd Sep 02
Location: Sydney, Australia
User status: Offline
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but the engines are the same right?
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Rob_Lee
Banned
Registered: 9th Dec 05
Location: Folkestone Drives: Nova 1.6 16v
User status: Offline
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quote:
Originally posted by VXR
THe orange bucket was used to clean the rear hugger which was quite dirty with gunk and oil...
Whats a rear hugger?
It that like someone whos in prison?
[Edited on 18-08-2006 by Rob_Lee]
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BabyBlade
Member
Registered: 5th Feb 03
Location: Hereford Rides: Ninja 600
User status: Offline
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someone got the shakes? 
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Daimo B
Member
Registered: 20th Mar 00
User status: Offline
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quote:
Originally posted by 3CorsaMeal
talking of bikes, i'm considering getting a twist and go scooter for work
Be prepared from abuse from drivers thinking your a 16 year old ned But in terms of cheapness, you cannot beat it. Fuel last forever, tax is £25 for the year, insurance is bugger all etc..
Monkey, basically yeah, small differences, but practially the same. K1 didn't have sump baffles etc..
Rear hugger is the thing that goes over the rear wheel. Stops all the suspension getting filled with dirt and crap.
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Ojc
Member
Registered: 14th Nov 00
Location: Reading: Drives : Clio 197
User status: Offline
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Did you blow it up? Did you deck it? What have I told you about trying to get your knee down in the wet? Your not Mr Rossi are you?
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BabyBlade
Member
Registered: 5th Feb 03
Location: Hereford Rides: Ninja 600
User status: Offline
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Just so i've got it right you've been riding this bike for a while and havnt just bought it with a knakered engine on the cheap?
take it its a straight engine swap, not a thou or anything 
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Siberia
Member
Registered: 9th Oct 03
Location: Leprechaun Land Drives : Zafira GSI
User status: Offline
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looks  did the old engine break? or is the new unit more powerfull?
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Half Pint
Member
Registered: 25th Mar 02
User status: Offline
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Scooter is £15 per year.....
well was in December when i got my new disk.....
been looking at SV's for when i do my test, think they are a great all round bike....
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Pablo
Member
Registered: 3rd Feb 03
Location: Milton Keynes
User status: Offline
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SV's are great!!! Sound lush too, good old V-Twin !
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Sidesport
Member
Registered: 25th Nov 03
Location: Bath
User status: Offline
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Nice bike, my friend has the same but modified!
Chap on the bike in front of him (red leathers) fell off wednesday night  , still in hospital with broken ribs, spleen in 3 peices, internal bleeding, broken arm and loads of other cuts and bruises. Got to stay in investive care for 2 weeks due to the bleeding.
Enjoy it, but go steady!
Chris
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3CorsaMeal
Member
Registered: 11th Apr 02
User status: Offline
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quote:
Originally posted by VXR
quote:
Originally posted by 3CorsaMeal
talking of bikes, i'm considering getting a twist and go scooter for work
Be prepared from abuse from drivers thinking your a 16 year old ned
thats what i crave, i'd get a little flag i waved at them, and stick loads of kinder eggs toys to my bike so people thought i was a total nut-nut
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Half Pint
Member
Registered: 25th Mar 02
User status: Offline
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Daimo has been riding for a while now and i think he is alot more sensible on the bike than on here
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Daimo B
Member
Registered: 20th Mar 00
User status: Offline
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Babyblade - Yeah, my own fault, blew the original up, big ends gone on it. Was playing with a 600cc Hornet. He lost out, but then so did I in the end Gonna strip the old engine for parts though. Basic engine swap, but we ended up doing a lot more work to it. Hoping to recover some of the costs of the other engine.
Tony - Yeah, prob £15, sure it is actually, it was a bit more as i had the 200cc one. Go for it mate, theres a good club, meets, rideouts etc. PLus someone lent me a special tool needed to remove the engine for no charge. Good bunch of blokes (and women). Its a great little bike, loads of torque at low revs. It runs out of puff above 80mph really, but carries on to mid 130's which is ample really, esp for commuting. Even Donnas got her full gear, boots etc.. Regulary go out for a ride. I've got 7 years road riding experience now too, my age is showing Insurance = £222 FC, Protected, 12,000+ miles per year, work use, pillion cover. Result!!
Sidesport -Always sad. Saw a biker crushed by a tipper lorry the other day, air lifted, 4" cut through his neck, but as far as im aware, he survived. I also had a guy on a GSXR750 come stonking along chasing me one day on teh a2, i slowed and changed lanes, he done the same, but too late, mis-judged his braking and went straight up the arse of a focus estate. Bike flipped over arse end over front, he went over the handlers. Was about 2 meters to my left at about 50mph... Surreal and slo-mo isn't the words... But, what on earth is that guy doing over-taking there with that van coming!!!
[Edited on 18-08-2006 by VXR]
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Cybermonkey
Member
Registered: 22nd Sep 02
Location: Sydney, Australia
User status: Offline
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quote:
Originally posted by VXR
Babyblade - Yeah, my own fault, blew the original up, big ends gone on it. Was playing with a 600cc Hornet. He lost out, but then so did I in the end Gonna strip the old engine for parts though. Basic engine swap, but we ended up doing a lot more work to it. Hoping to recover some of the costs of the other engine.
Tony - Yeah, prob £15, sure it is actually, it was a bit more as i had the 200cc one. Go for it mate, theres a good club, meets, rideouts etc. PLus someone lent me a special tool needed to remove the engine for no charge. Good bunch of blokes (and women). Its a great little bike, loads of torque at low revs. It runs out of puff above 80mph really, but carries on to mid 130's which is ample really, esp for commuting. Even Donnas got her full gear, boots etc.. Regulary go out for a ride. I've got 7 years road riding experience now too, my age is showing Insurance = £222 FC, Protected, 12,000+ miles per year, work use, pillion cover. Result!!
Sidesport -Always sad. Saw a biker crushed by a tipper lorry the other day, air lifted, 4" cut through his neck, but as far as im aware, he survived. I also had a guy on a GSXR750 come stonking along chasing me one day on teh a2, i slowed and changed lanes, he done the same, but too late, mis-judged his braking and went straight up the arse of a focus estate. Bike flipped over arse end over front, he went over the handlers. Was about 2 meters to my left at about 50mph... Surreal and slo-mo isn't the words... But, what on earth is that guy doing over-taking there with that van coming!!!
[Edited on 18-08-2006 by VXR]
i suppose you think the Foci driver was at fault 
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Jambo
Member
Registered: 8th Sep 01
Location: Maidenhead, Drives: VXR Arctic
User status: Offline
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Daimo, not think of putting an XE in there??
Good thread 
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Ojc
Member
Registered: 14th Nov 00
Location: Reading: Drives : Clio 197
User status: Offline
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Have you de-restricted your bike yet Daimo? What can you get out of it on a flat with your head down? Fastest I got was 72mph down a long road.
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Marc
Member
Registered: 11th Aug 02
Location: York
User status: Offline
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quote:
Originally posted by VXR
equipped with Tea
Is that an in joke?
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