94 Winter dismantle, clean up, & minor customize

[steezin_and_wheezin]

Great work, we're getting spotty rain here too. Even got some SNOW yesterday! not enough to stick, but enough to make my cheese all day. man i miss the winter...

Following this thread makes me so antsy to get Gabby(my 06 no longer parts bike) up and running.

Can't wait to see the new heart transplanted!!

[Tombstones81]

Motor is IN ! 

Finishing everything up.

Just got done torquing down the bolts and then swapping the motor side carb booties.
Yes adidas, they are a better fit (older vs newer) on the older carbs.
The 01 booties, they just didnt sit flush very nicely.
Tossed my almost brand new 94 ones on and they are Sooo much better.

if whatever u said or asked before was to confirm if theres a difference.

kk gonna see what I can finish up before it rains or my time runs out.

Pics later and hopefully shes runnin by the time I gotta go to bed for work tonight!

(edit)
would of had pics but while I was letting the paint dry, I came inside.
Emptied my pockets and put my nasty oily jeans on for the big job and forgot to grab my camera.

when im done they will be uploaded!

[Tombstones81]

ITS ALIVE!!!!..... again! hahahahaha

ugh Im freakin BEAT!

8:30am to finishing the clean up at 1:30.

Repainted parts of the frame I scratched up.

Came back inside while it dried.

Installed my new 15T sprocket.

Put the motor in, which went VERY smoothly!!

Bolted the sucker down.

Changed engine side carb booties.

Hooked up all the wiring.

Put the carbs and air filter in.

Ran all new hoses.

New header gaskets in and put the exhaust on.

Then she started Right up!
even after sitting for I dunno how long with the battery not on a tender!
I did put it on for some extra juice right when I was starting it as I forgot to earlier.
I'll put it on to Fully charge when its not going to rain as it might later and im in my boxers for bed.

Engine in and bolted down




everything but the exhaust on.
with brand new hoses 




and here she is right before I started it


and the very first crank caught on camera for once.
as I knew I wasnt going to be embarrassed this time! hahaha



and it died when I took the choke off because I had to adjust the idle screw.

took it around the block after tightening the chain.
Ran like a Dream!

[cbrfxr67]

Tomb looks great!  I hope I can clean my 929 engine as good as you did yours.  Loving it!

[Tombstones81]

Thanks!

and as usual, not all the props go to me. hahaha

the engine already was in "Almost" pristine visual shape.
was merely dirty from sitting for 3 years prior to the seller getting it.

was just some debri in the fins next to the spark plugs.
Rust on the original sprocket and holder (whatever its called) but I cleaned that up good and my 15T sprocket is brand new.
and rust on the timing on the other side from the old cover being cracked.

other then that, was just dirty.

Put my old scratched up (more grey then silver now) cover on to replace the cracked one.
no emblem tho.

around $35 for a brand spankin new right side cover.
So I think I will order one next pay from the dealer I've been ordering through and save my new extra emblem for that one.
but also order a replacement emblem for the left side too.
but in the meantime, put something over the cover I put on which has no emblem on it either.

I would just try to find a cheaper used side cover but the engine is in such pristine condition.... I want brand new!!

kk got some fresh gas in a container this morning.
as there seems to be a "Little" bit of rust "particles" left in the tank I seen in the lines.
So im going to flush it once or twice more with gas, fill it up and go for a long test ride!

[cbrfxr67]

Tomb, want me to see if I have that side cover?  I haven't looked but might be in perfect shape, just sitting in the basket case. ()

[Tombstones81]

Cool!
be my guest!

[Tombstones81]

Sprayed and wiped her down.
Cleaner then its been but not Scrubbed and waxed yet.

Took some better pics, now time to wash up and Ride!!!









not wasting a brand new emblem, so I just put a black one on it for now as the extra silver one I have has the hole in the middle open.


my 2 babies!




my 2 babies again and my dad in the background

[Tombstones81]

     SCARYYYYYYYYYYYYYYYYYYYYYYYYYY!!!!!       

Went for a nice hour ride around.

Running a little lean.

Other then that, no motor problems 
Rode great.

Until I Really opened it up going up this one hill!!

Friggin chain jumped on me!
WOW did I freak out! hahaha (emotionally, not physically)
I just let off the throttle, calmed down and very delicately rode home.

Had the throttle wide open, engine screamin, all of a sudden it acted like it went into neutral and I hear a quick light clank.
Then fine.

Got home, chain was a little too loose.

First time thats happened, was Not fun! hahaha

(edit)

Well, checked the valves against the wishes of the seller....
hahahaha I guess he didnt trust me after my horror stories!

I was hesitant because if something went wrong... I'd be kickin myself for not checkin.
but if something went wrong checkin, I'd be kickin some more.

So I went at it VERY carefully! hahahahaha

Intake were at .06.
exhaust, one was at .07 (good)
other one was at .05, so I took it up a little bit.

Finished up.

Started up smoothly.
Sounded better then before.

Rode it around the driveway a bit.
Seemed to ride better now.

So after I change the right side cover and 2 new emblems.
then jump the main jets from 145 to 150 (little lean atm)

can safely say now that she is DONE!

unless something natural breaks.
isnt anything wrong with it now tho!

ahhh so nice!

(edit)
back from another yet longer ride after checking and adjusting the one exhaust valve.

Rode even better.

So Stoked!!!

Still a little lean tho.
Will just order 150 main jets next Friday when I order the new emblem and new right side cover.

and it actually wont be completely "finished" until my T O M B S license plate arrives in early May hahaha

[Tombstones81]

Quick small update.

While its not raining yet.
decided to go out, take off and repaint the peg mounts black enamel to match the frame.

From the location, they are not very easy to keep the paint in good condition.
At least not the red from all wear they get.

The black enamel will hold up better I think.

Also looking at the newest photos.
Im just not too crazy over them being red.

Dunno what it is, they just dont match the bike now to my eyes.

kk out I go!

(edit)
and im certain they will look better black but with red pegs when I get around to buying them.

[Tombstones81]

and just like that, finished 

redid the chain guard too since I initially did it in the duplicolor crappy clear when I did the headlight cowl.
this time with the good $h!t!

but now the shift lever looks out of place being red.... hahahahaha
Oh well, that will take more time waiting to dry then to paint since its so small.... another time.

the ONLY non Suzuki sticker going on my bike!
Glad I got the white one, sucker REALLLYYYY stands out!


Bike also got one quick layer of wax yesterday.






While the paint was drying between coats.
Actually stopped and stood there staring at the bike appreciating all the hard endless work that went into it and the pretty much Finished product!

im an oddball who does that all the time with things, stop and smell the flowers so to speak.

Started doing it after I BUSTED my rump makin money to buy my First and Second cars.

Used to just stare out my bedroom window at night at 18 yrs old just enjoying the view and lookin down thinking, cant wait and it would be so nice to stare down at my own firebird! (my #1 fav car)

Eventually got #1 then #2 and did the same thing, stared out the window at both of them appreciating my hard work paying off.

1st car, not mine but it was Exactly the same minus the side tinted windows. (93 firebird 3.4ltr)


2nd car. (94 Trans am 5.7  lrt 350)


(edit)
got bored again! hahaha

Shift lever and kickstand now black and drying.

Looks alot better now

[Tombstones81]

Been quite awhile since I updated this.

First change I did after repainting the peg mounts.

New side cover and emblems.

it wasnt straight when I took the pic but fixed it after.


new side cover and emblem.


busted my @$$ for hours cleaning up the muffler after having it welded on finally


repainted the pipe


was swapping out main jets and had the tank at a bad angel when it was Full and gas poured out the cap and down the back for quite some time. (like 10 mins)


stripped and prepped for repaint


repaint came out badly.
I needed to sand down the bondo better with finer sand paper.
you can tell up close if you actually look for it.

and was finishing up the painting when it was getting dark out.
but still light enough to paint......
Just not enough to notice friggin lint particles on a few areas of the tank!!!!

So there is like goosebumps on parts of the tank ><

still got plenty of paint left, so I will be redoing it once shes back to 100%.


and the most recent Hell!!

to make it short.....
after getting the pipe finally welded and put back on....
it wasnt 100% properly installed (by me of course! ><)
so from all the popping because of an exhaust leak prior to the weld, and also thinking partially a carb problem too.

I didnt think much at all when it was popping after putting it back on after it was welded.

Took it for a good 3 to 4 hour group ride with a bunch of locals.

So by the end of the night, noticed it got pretty damm loud at the headers.
checked, soot all over the headers....

figured the pipes were funked.

bought a replacement stock exhaust because I was sick of fiddling with the piece of crap!

waiting for it to come, I got impatient and fiddled with the exhaust some more.

got them sealed but noticed it would bog at higher speeds between 25% and half throttle ish.
or 50 to 75%.
I pretty much couldnt just cruise along and maintain say 50 mph with set throttle.

it would act ok as i let off the throttle to slow down.
and when I gave it throttle to accelerate.

convinced I messed up the valves, I started checking.

first, what I could check with the cylinder head still mounted.

the one exhaust valve tightened like .08mm's in say 1500 miles from my initial check.
the rest were still spot on from the initial check when I first put the motor in.

got that dealt with.

acted better but still signs of boggin.

also no signs of the valves not sealing fully.

So, I said the heck with it and took the whole top end off the motor.

Cylinder walls were fine but needed to be honed. (got that done)
Pistons and rings were fine.

valves were sealing properly.

but just to be sure, I removed the left exhaust valve that tightened up .08mm in 1500 miles.

valve guide on the bottom cracked ><

So!......
I look up how to remove the valve guide....

Heated up the head and proceeded to remove it....

slipped, mashed my hand against the edges of the head and sliced my finger pretty darn good....

Also, took a nice chunk out of the metal "Around" the valve guide.....

Which totally Funked the head!


So now im buying a black replacement cylinder head from adidas that is all there and all the original parts together.

Once that arrives, it should go right on and not have a single problem!

Before installation tho.
Gotta clean it up, strip and file / sand it down and the cylinders and repaint it to match the rest of the engine.
Repainting the cylinders too just incase the paint doesnt match up 100%.
So if the entire top is a lil different shade then the bottom, then it wouldnt really look bad.

if just the head is, then it would.


Also have some custom gauge overlays coming from Ford 



will match my license plate that finally arrived like a week ago.



UGH!!!
okay thats it for now!


oh yeah.
the POS exhaust that gave me so much trouble.
MIGHT be fine.
Was my fault trying to get the muffler mounted to the Outside of the mounting area.
on the inside it would scrape on the rear brake bolt that sticks out.

but I dont care.
got a stocker that is in Great shape!!!! Tnx Steez!!
so the old one is goin to the scrapper! (not giving anyone my bad mojo!)

[cbrfxr67]

"Update?"  I thought, and started reading. 
Tomb you gotta get a project bike on the side when yours is running good, just for the thread alone! 
That really sux on your tank.  Ugh I know exactly how you felt when you saw it. 
And only you too, would say F- it and open up the whole top end on a whim!  Cracked valve guide wtf?!
Still watching and hope you get this stuff sorted out too!

[Tombstones81]

"Update?"  I thought, and started reading. 
Tomb you gotta get a project bike on the side when yours is running good, just for the thread alone! 
That really sux on your tank.  Ugh I know exactly how you felt when you saw it. 
And only you too, would say F- it and open up the whole top end on a whim!  Cracked valve guide wtf?!
Still watching and hope you get this stuff sorted out too!

Actually the tank didnt really bother me.
What I did get mad and curse furiously about was my "bad luck".

I mean Really?!?!
I've taken that tank off Sooo many times and have the fuel lines long enough where I dont have to disconnect them.
Just put the rear of the tank to the side on a chair with the front setting on the frame.
Never a problem before, but this time I had a FULL tank of gas.... hahaha

Well, I had no choice but to open her up.
I eliminated All other possibilities first tho.
Wasnt the carbs or the headers this time.

Valves were the only possibility left.

and nothin left to sort out 

Just need  to replace the head.
Repaint it.
Also repaint the tank (only takes an afternoon)
Put it back together and be golden.

Honestly, the Very Last problem I had was with that POS exhaust I had.

Tnx to Steezin, that problem has been fully eliminated 

[Tombstones81]

Update! 

UGH what a day!!!
Been at it since 9am, now 6pm almost and still not finished!!

Started out degreasing and cleaning the chain up.
Wiped it off really good and let it sit as it was for good few hours before regreasing it.

Took my headlight off to clean up the wiring in the front.

Removed my gauges to install the new custom overlays from Ford.
Never liked the black frames.
So!, I painted them Red to match the rest.
Also painted the needles Red.
Came out GREAT!!!!

Dont mind the zip tie on the right, snapped the bolt weeks ago and keep forgetting to stop for another.



actually JUST got done with that as I had to leave the frames dry all day from all the handling I would be doing putting them back together.

Got the cylinder head replacement from adidas today 
THE MAN!!!!! 

Almost ruined my entire engine tho.
Not his fault as it was an extra one of his he bought but never used.
So I am 100% certain he knew nothing about it.

but, the intake cam shaft sprocket was loose Quite a bit!
if I didnt notice it, it would of been BAD!

Surprised I did as I wasnt totally sober at the time! hahahaha 


Installed the head.
Bolts torqued down correctly and in order.
Cam shafts went in just fine.
Left exhaust was at .05 clearance with a 260 shim.
Tossed in a 255 I had and shes all good.
All 3 other valves were at exactly .08 clearance each! 

Put the cover on and only hand tightened the cover bolts as I planned to leave it run for 5 to 10 mins and then check the head bolts again.
Put everything back on.

and

SHE LIVES!!!!!................ Again!!........ hahahahaha 

Sounds Alot better then before!
especially with the stock exhaust from steezin too! 

Only have to fiddle with a Slightly hanging idle.
Most likely just a cable adjustment as I really didnt get Everything down Spot on perfect.
The minor things that is.
Was just getting it to the point where I can see if it starts and runs good.


So, break time!

Then I gotta go out and check the head bolts.
Tighten everything down properly.
Put the headlight back on.
Adjust the throttle cable and go for a ride!!! 

[Tombstones81]

Yes this deserves a whole nother post of its own!

I forget who said it, I think adidas but I cant find the msg again.

My bike is "Officially" the Gstwin.com Whore now!  hahahaha

I think I have more parts on that bike and for that bike from other members then any other member!
hahahahaha

I find that hilarious!

I honestly dont even wanna list it all, my brain will hurt!

[cbrfxr67]

Good stuff Tomb!   !

[Tombstones81]

Indeed!

1 to 2 hr test ride last night was good!
Not a Single decel pop! 

So, this morning I went out and about for more bike goodies!

Fresh oil, filter & plugs.

Paint for the top half of the engine.
and more black enamel to touch up visual areas of the frame from all the work again.
and also because the one side had a few minor annoying run spots from the last time that I need to sand downa nd repaint.

Also picked up 2 blue LED strips to light up the engine area 


Just got back home.
So I will be getting to work on this whore in a little bit.
Pics when I'm done!

[Tombstones81]

FINALLY finished for the day!!!

but no I wasnt working on it til now.

Worked on it until like 5:30pm.

Repainted the entire top half of the engine.
VHT engine paint, went with the closest color based on the cap (wont do that again)
Top half is pretty much totally friggin Silver!
Bottom is more of a grey'ish silver.

but it looks GREAT!

Between coats, had nothing better to do.
So, I sanded down and repainted the exhaust pipe.

That came out VERY nice as well!
even tho it was fine to begin with, but I wanted a Dark shiny black finish like my last exhaust.

Sanded down and repainted the visual areas of the frame.
Also came out Great!

After that, changed the oil and Didnt snap one of the stems this time! hahaha

Put the new spark plugs in.

Then sealed up the head cover better as it was Very slightly leaking last night. (not a single drop now)


Left it run for a few mins to heat up and cure the fresh paint.
then let it cool.

Planned to do that a few more times but it was Bike night at a semi local restaurant.
and I only had an hour and a half to finish up, put all the tools away and clean up to leave.

Before that tho.

Installed 2 blue LED strips in the engine area.

Specifically, on the inside of the frame from near the rear shock area to almost right next to the carbs.

Night came.
Looks GREAT!
Even the fellow riders said it was Very noticeable!
even tho it was only 2 strips int he middle of the bike.

Now I plan to get 2 more to place above the rear tire.

and.

did a nice 150 mile ride today/tonight.

Running just fine.
Minus one little hiccup.
Was pushing it in 6th and it started to bog and then died as if fuel starved.
Just like it did when my headers were leaking.

Stopped, turned it off for a min and started right back up.

Was Right about to hit the reserve line, so I guess it was fuel starved as the headers are not leaking at all!
not even a single pop Anytime today.

I'll get pics tomorrow of my work.

and tomorrow night a pic of the bike lit up with the 2 LED strips.

just Way too exhausted tonight to even move from this chair except to bed!

So!
Good night 

[Tombstones81]

Okay nm.
Went out and got pics.





















enjoy!