West Seattle GS500 Build from Scratch - WE DID IT! Meet PHENIX!

[bombsquad83]

Where is Jessie?  I'm sure he can give you a definitive answer.  Definitely helps to have 2 sets of hands...

[Kijona]

So counter clockwise means the oil cooler ends up on the outside of the left side of the frame. Engine then is still trapped. Or is it just a little bit counter clockwise?

Some say rotate it clockwise.

Buddha says lay the bike on the right side on a mattress.

Now I am confused.

Maybe I should try lifting the frame up and off of the motor? 

That danged welded on bracket for the horn on the "F" frame gets in the way. Maybe I'll amputate that thing. It IS a "dead-title donor" frame. Always easy to mount a horn anywhere with bailing wire, duct tape and some chewing gum if the frame is used again.

Anyone want to come over and help?

I like how the Haynes manual says:
"21 The engine can now be be removed from the
frame. Check that all wiring, cables and hoses
are well clear. then lower the jack and
manoeuvre the engine out of the right-hand
aide of the frame"

Just hack that frame to pieces. Make "genuine suzuki" key chains out of it.

[adidasguy]

Well, thanks for the comments. It got me thinking. And then - it came to me....,.

First, all the bolts were removed last night. Then I got stuck, as you know.
I studied it and decided counter clockwise was best. I noticed the rear would clear the frame. So first, rotate the butt end to just clear the frame.


That leaves the front inside and still stuck. Take off the cover? I started to then looked again. I could rock the engine but still would not clear the frame.


I saw the back end was clear of the frame - enough to start lowering it. Would that let the front clear the frame? Would the oil cooler get caught on the left side?


The back end - with a little more turning - was completely clear of the frame. The front still caught. So I can safely lower it more without scratching the back end. The left side was now clear of that side. More lowering


And there it is. The back end was turned out enough to clear the frame. Now lowered enough for the top/front to clear the frame.


Here it is! Ready for a valve adjustment and a good cleaning before going into Phenix. None of the wiring was removed. Should go back in real easy and start right up. Wheels and forks removed from donor - that took just a few minutes. Cleaning up all my mess is next.


After putting the forks away from the donor bike, I realize I should spend a day fixing forks then sell them.

[knowles]

You should have i was in need of a good pair. i just bought a par off an 07 for $100, with new seals. 

[adidasguy]

Put chain on Phenix in preparation for the motor. Also, the chain tool will go out on loan to a member so why not get the chain on now?


Riveted on with the chain rivet tool. Not cheap - but it really makes the job easy - 2 minutes tops.


Also cleaned a bunch of parts from the donor parts bike. Now to dry and sort them. Sprocket came out good and still usable.

[mattnes17]

What in the world are those little green triangles and where do i get them???

[adidasguy]

Cleaning media for a vibrating parts cleaner. More infor here. The have different sized and prices...
http://www.eastwood.com/18-lb-vibratory-tumbler-kit-inc-2-bowls-and-media.html

[mattnes17]

Cleaning media for a vibrating parts cleaner. More infor here. The have different sized and prices...
http://www.eastwood.com/18-lb-vibratory-tumbler-kit-inc-2-bowls-and-media.html

The tumbler itself is a bit spendy... I could probably build a home made one for 50 bucks. hmm... or maybe just a wire brush and some carb cleaner will have to do for now. haha

[bombsquad83]

Also cleaned a bunch of parts from the donor parts bike. Now to dry and sort them. Sprocket came out good and still usable.

drooling....daddy likey vibrating tumbler for parts cleaning.

[adidasguy]

They have a smaller one for $99. also includes the media so really about $60 for the unit. Comes with 2 bowls.
http://www.eastwood.com/5-lb-vibratory-tumbler-kit-inc-2-bowls-and-media.html

I can't live without it. all the crap goes in it. Removes rust, corrosion, grease. Turn it on and take parts out 6 hours to the next day (I run it over night).
Then put parts in the polishing stuff (ground up shells & stuff like that) and all - especially chrome bolts - come out like brand new.

Think of the time you save. Turn the machine on.... watch the uncensored DVD's of Family Guy.... come back to spanking clean parts.

The bowl needs to seal so cleaner and crap doesn't fly all over the palace.. There is a science to the angles, frequency and amount of vibration so the parts continually tumble and rotate around the bowl. Without good tumbling, parts would wear scratches in other parts and certain areas would be clean and other areas dirty. For $99 for the smaller one - you can't beat it. I got the bigger one after having a smaller one so I could do heel guards, axles and bugger stuff.

Isn't this worth $99? Compare. Yes - I'm selling you on one of these because I can't live without it. Most useful cleaning thingy in my Bike Cave.

[Grommett2k]

Something like that would be very handy when I start tearing into the Savage project I got from my father in law.

[bombsquad83]

Holy box-o-bolts batman.   Screw getting a cleaner,  I'll just by clean bolts from you if I need them. 

Kidding...

[Funderb]

adidasguy, I used to have a baby tumbler for brass, but its gone now, my question to you is:

When are you going to make your own that you can plug a gas tank into and tumble it clean?

If you use corn or nut media it self-burnishes for a durable finish!

[adidasguy]

We need one of these for a gas tank to spin & rattle it clean

[Tombstones81]

Coming along Very nicely!!

Bookmarked the cleaner incase I ever plan to disassemble the bike again.
or a future project.

Insane how clean those parts come out!

[knowles]

That is sweet i would love to have one, once i get done with school i will be buying one of those.

[adidasguy]

Cleaned the engine. Wow! What a bunch of crap under the clutch cover and a total lack of any grease there. Just oak tree seeds, crap and metal shavings from the PO not oiling the chain. In fact, when I got the 2006 bike for parts the tires only had 20 psi. If I didn't part it out, I'm sure it would have died in 6 months from lack of maintenance. I feel good saving a bike from the scrap heap and a bad owner.

Engine clean and did valve adjustment, too.


After today's group ride I finished the cleaning then decided to try putting it in.

First picture at 6:09pm


All finished at 6:26pm. (*Note to self: remember there are 4 engine bolts - not 3.  )


I didn't realize it was that easy to put an engine in. Is it? or was I just lucky? Or did I learn how to do it by reading all the posts on installing and removing an engine? Look at the picture of the crap that was under this clutch cover.




Looking good! Note to self: replace that black frame cap with a silver one. Interesting to find there was one original threaded hole next to the horn mount that fit for the oil cooler. What was that bolt hole for on a 1993 frame? Just have to drill and tap one more hole for oil cooler and 2 for the oil cooler lines brackets.


I see the end is in sight!

Now I have to start thinking of the color scheme. So many choices.....

[knowles]

I would have painted the frame when you had the engine out, I don't like the silver frame. might have mine powder coated over the winter.

[adidasguy]

The frame was repainted before I got it - which is why it is so clean. The motor was never taken out of it. I bought the bare frame already repainted. Clean title, too.I think someone was going to rebuild a 1993 then found they had a crap engine. Most bolt holes never had a screw in them. The engine mounts show signs someone did put an engine in then took it out.

Bike #2 will have the frame powder coated gold to go with purple tanks and plastics: i.e. U.W. colors. A Husky bike will be really cool in Seattle.

[adidasguy]

Phenix wants to LIVE!

Just for fun and giggles I connected up the remaining electricals from the engine. Pressed the starter and he cranked!
He still needs the carbs and exhaust. But I think next weekend Phenix WILL BE ALIVE!