I had to rebuild 4 times alrdy my engine! Need expert help... bob, dgyver,etc..

[CirclesCenter]

BUMP

PAGING DR. KERRY. DR. KERRY TO THE OPERATING ROOM.

BUMP BUMP

I don't think you could ride it hard enough to cause a problem after a fresh rebuild anyways. I mean yeah, not a good idea, but still I don't think that would be it.

Yeah the welds sound like the problem to me. But I'm only a nurse, Kerry is the Doctor.

It gets up to 110 here in the day and my bike doesn't mind so long as I don't get stuck in stop and go traffic.

editted for temp stuff.

[starwalt]

Kerry would be the first to mention that this is a little out of his realm....on the other hand, if he had the spare engine I have here in the garage, he'd be making great photos of the insides! 

Bob B, Srinath, or dgyver are the ones to look this over.

Filipe_500: You have gone way beyond the point of return on this engine. I would be worried about journal mounts and unseen case cracks due to impact. Your devotion to the GS will make you a legend, but it won't save this engine. Surely in all of your beautiful country there is another GS parts bike to be had.

Search for a used engine. Do not spend any more time or money with welded crankshafts --  I side with Sledge et al on that.

You might as well start working on this yourself. At least you would gain some experience and couldn't do any worse than others. 

[CirclesCenter]

Sorry Starwalt, not being specific, just being a jackass...... Imaging being in a GS hospital, "Paging Dr. Starwalt to the OR"

No offense intended.

Just being a jackass, that's all.

[sledge]

Wise words indeed from Starwalt.
Filipe?
THROW THE WELDED CRANK AND RODS AWAY......they are not worth their weight in sh**!
The WILL fail again. A built up weld on a crankshaft journal  simply will never be as hard as the original parent metal, hardness is critical for this application and a welded surface will wear and fail in no time at all...PERIOD. Thats assuming the crank is in balance, is running true and has not been twisted by the heat generated during the welding process. Also that the journals have been machined within tolerance and polished to the correct surface finish. In the official Suzuki service manual for the GS5 of which I have a copy, I refer to section 13-4. It  lists 10 critical dimensions relating to the crankshaft and con-rods for the 95 model (same as mine incidently ) . Its vital that the rods and crank, be them new or 2ndhand are properly checked with suitable and accurate  instruments and the dimensions are found to be within the tolerance stated by Suzuki, otherwise you are compromising reliability. This is precision  engineering and remember we are talking now about tolerences of 100th of 1mm. Your Mechanic has to be comfortable working to these figures to effect a reliable repair,  he must have the figures to hand for reference as well as suitable and accurate measuring instruments. I doubt very much he will have otherwise he will have got it right first time.
If I had a scanner I would gladly send you a copy of the figures for reference, unfortunately I dont. Perhaps another member who does own the manual and a scanner will send you a copy to pass on to your Mechanic. Personaly, like my colonial friend Starwalt states I think you have gone as far as you can with that engine, I would write it off and find a complete and low mileage 2ndhand one and simply start again. You dont know what strains and stresses have been imposed on its (apparently undamaged) component parts during the repeated failures and you have obviously (and correctly in my opinon) lost faith in your mechanic. This final comment goes without saying......I wouldnt hesitate to demand your money back from the mechanic. Threaten him with legal action if he refuses. Here in the UK he would loose hands down.

[starwalt]

...... Imaging being in a GS hospital, "Paging Dr. Starwalt to the OR"

I work in hospitals and have been paged too many times.    The OR is the last place I enjoy working. Haven't really been in there in years. As a matter of fact, the last OR I was in was in Haiti (way off topic, but a really cool story). I'm on vacation this week and hope to not see the inside of any health care facility or more specifically any MRI scanner.

No offense intended.

None taken. I just didn't want anyone to be getting hopes up for a Kerry solution here. He's just super at so many things except engine internals. Poor Philipe needs a transplant here.  Anyone in South America know a donor?

Just being a jackass, that's all.

Well...maybe you will outgrow it.    It is probably not genetic.

[sledge]

By the way......bad luck in the World Cup...I had a small bet on brazil winning!!

[starwalt]

Regarding the delaminated/broken rotor magnets...

Filipe, here on GSTwin this is referred to as "Goat's Syndrome".  It can occur naturally in the life of the GS, but in this case I wonder if the magnets struck the stator windings due to eccentricity while rotating? The tolerances are vital and without a lot of room for error.

Again -- it is donor engine time for this GS.  

I vote we petition Srinath to name this cycle of repair/failure "Filipe Syndrome" or more accurately "Filipe's Bad Mechanic Syndrome." I've seen some desperate things done to repair machines in 3rd world countries, but Brazil is not 3rd world and surely better can be done here.

Sledge has a good idea when it comes to the manual pages. I too have a  Suzuki manual (actually two OEM and a Clymer and a Haynes) and can scan the important pages for your reference if needed. All I would need is an email address to send it to. PM me with it.

[sledge]

Starwalt?
"FBMS" sounds good to me, he does deserve some recognition, both  for his persistance  but more importantly the amount of cash he has handed over for what has turned out to be 4 worthless repair attempts. 

[Filipe_500]

Hi mates!

Thanks a lot for your moral help   BUT, I dont want my name associated with a GS500 failure! hauahua... I´ve spend over a year and tons of cash on this bike to have this engine not working propelly .... I would accept have my name associated with a very modifided GS500 tho!


I just have few questions now!

- I just got a used crank but in really good shape! Do I have to rebalance it, or its balanced already and i dont have to do anything?

- My email is :  filipe.carpes@terra.com.br   / I REEEAALLLY would apreciate a pic of the important pages of this manual...!!

- I just brought a new oil pump, a good crank, new rods, new WISECO pistons with rings and piston pin, new bearings....   I shoudnt have a prob. now, right?!

-Does anyone know how to stick a oil cooler on the GS? i would like to stick a oil pressure gauge and oil temp gauge as well... I´ve searched ALL topics around here, but couldnt find anyone who actually done it!



Thxxx
Filipe

Btw: No one in Brazil can believe how bad we played against France, if even we have played good... its ok to loose, but it was a shame...  

[sledge]

Starwalt is happy to send you a lifted copy of all the critical dimensions via email and I am sure he will. Its vital you have the crank and associated dimensions and the run-out checked by someone who KNOWS WHAT THEY ARE DOING.  It will do no harm to have the crank and rotating mass balanced. Also make sure the bearing shells are the correct size to suit the crank journals and housings as there can be variations during manufacture/assembly. The GSF has an oil cooler as standard, dunno whats involved in fitting it to a GSE, if there are no mods to the block/head between the models I cant see it being difficult to fit one.........One last tip, find a better mechanic, ask other bikers for recomendations or try the bike magazines.

[Filipe_500]

Hi guys,

i´ve just remembered i did some movies with my bike...

http://rapidshare.de/files/25506346/14_08_05_008.mpg.html  This is before the engine break first time!
If u pay attention, u can hear a metalic noise coming from it! At this point, i felt my bike wasnt as strong as when i first got it, and the bike had a lot of vibration, especially at 5-6 k RPM!

http://rapidshare.de/files/25507677/marcha_lenta.MPG.html This was before the engine break last time!


I´m still trying to find some oil coolers solution over the internet hope i find it within another 5h at most

[Kerry]

Oops - how did I miss the updates to this thread all day?  I guess it kept getting bumped to the top, and I tend to work from the bottom up. 

Kerry would be the first to mention that this is a little out of his realm....on the other hand, if he had the spare engine I have here in the garage, he'd be making great photos of the insides! 

starwalt is absolutely right.  I don't have all the answers ... just about none when it comes to engine internals.  That's 'cause I've been lucky enough to not have to open mine up yet!

As it turns out, I actually DO have a spare engine in my shed.  (From richard running my former '96 without oil. )  But all I have done with it is steal the valve shims. 

You might have noticed that I stay out of most rejetting discussions, too.  My carbs still have the brass plugs in place. 

Bob B, Srinath, or dgyver are the ones to look this over.

Yep, and I noticed that Filipe_500 listed 2 of them by name in the original thread title. 

[sledge]

I am still `plugged` too. Jetting, exhausts air-boxes and other mods are not really my thing. I like older bikes that look like they just came out the crate and run the way the makers intended. That doesnt mean to say modding is a bad thing, we all enjoy our bikes in differing ways.

[starwalt]

Ok Filipe_500 you have 4 emails coming your way. I broke the scanned pages up in case your ISP limits download size. Scanning them in black&white plus cropping helped. I sent the specification pages for the area you are working in AND the service also specific to the crankshaft and conn rods.  I hope it helps.

Well gents, I pulled my brass plugs simply because I was doing a complete tear-down of the carbs. I've been taking some vacation this week and got all the electricals on the GS rebuild completed. 

I even ventured to turn the engine over with the start button -- it turned over just fine thank you.  Three cheers! Love to hear the thump-suck-thump-suck sound of pistons moving.

The list of things to do is very short now. Just waiting on a parts order from MR Cycles and I'll be hooking up the carbs soon afterward.

I just may get this thing running before my coworker sells me his identical painted 90 GS.

Maybe.

[Filipe_500]

hi mate!


Have u send it alrdy? i didnt get anything yet!


Thx a lot!!


Filipe

[Filipe_500]

up!