Rebuilding Junior - died and LIVES AGAIN!

[slipperymongoose]

Yes Adam you'll have to split according to the Haynes manual.

[adidasguy]

Is there anything the West Seattle GS500 Club can not do? In 6 hours we built a new engine from parts of 4 different engines. It works!

Junior is ALIVE!

http://youtu.be/9GJvzwadV18

11:30am: We have a head.


11:40am: We have a body


11:50am: jmill and bluesmudge arrive for the operation.


(Slight break for Pizza and Hot Wings.)

2:20pm: The operation is midway through. The transplanted parts are working. No signs of rejection. Timing and valves now getting adjusted.




4:00pm: The new heart for Junior is ready to be installed.


5:30pm: The engine WORKS!
Junior is ALIVE!

[Bluesmudge]

Great success! I was amazed how effortlessly we created an engine out of parts that had never met before. Almost no issues other than the quick problem with the exhaust header bolt.

[codajastal]

Is that a postie bike I see in the background?

[Tombstones81]

Very nice!!!
and Very lucky considering my crap luck trying to do the same with my 2 extra motors. hahaha

[adidasguy]

There are minor running issues. I think all that needs to wait until all these parts start working together. There might be minor issues or organ rejection. A little living, riding and cleaning should do wonders for recuperative therapy.

Once he gets 100km on the clock, we can take a second look at the carbs, valves, plugs and make sure everything is still tight.

I got the rest of the frame on. Tidied up some wiring. Ran him some more. Connected up the throttle and choke cables. All that's left is the tank and belly pan.

Saturday will be a day of cleaning up the Cave, cleaning Junior and test riding.

I am so amazed that we did this in 6 hours. Unbelievable! And that frankenstein of a motor ran the first time we hit the starter!

You guys were amazing today. and you both got a hit of karma korn, too!

[adidasguy]

Is that a postie bike I see in the background?

You mean the TS-185? (Thumper) Or Austin's 110 parked next to James' newly painted white GS500? (That's a fun little bike!)

Tomb: 4 motors of parts increases the odds of making one working motor. 2 motors worth of parts might not be enough   

[Tombstones81]

hahahaha!

Well actually!
2 complete motors as far as parts go.
But total parts from 3 different engines.

You probably totally avoided my biggest problems.
Which were the cam shafts.

the 95 cylinder head went on the 89.
but the 94 cam shafts that worked fine in my 94 bottom with 95 top end didnt wanna work right in the 89.
but the 89 bottom and cylinders, with the 95 head, & the 89 cam shafts worked better.

So you might wanna just pay attention to top end noises for a little while.
Though im sure you know that. hahaha 

Good job getting it all together tho! 

If I lived out that way and helped, cut that time almost in half for how many times I've done mine alone. hahahaha 
oh the horror!!

[codajastal]

You mean the TS-185? (Thumper) Or Austin's 110 parked next to James' newly painted white GS500? (That's a fun little bike!)

Yes Austins CT110 Great bikes that go forever  I have 3 of them.

[jmill]

Yesterday was a great day for work. i can't believe how fast we were able to get everything going. I thought it was great when all three of us were standing above the bike with none of the controls hooked up, manipulating it all directly on the bike. It even LOOOKED like open heart surgery 

[canucklehead]

Congrats on the transplant... nice to see the patient back on his feet 


Griff

[Phil B]

Is there anything the West Seattle GS500 Club can not do? In 6 hours we built a new engine from parts of 4 different engines. It works!

Junior is ALIVE!

Muahahah.. frankenGS !

Nice!!


.. wish there was a gs club like that in the LA area.. sniff...

[scottychop]

Congrats!

[jestercinti]

Gotta hand it to you Adaidas...You did it again.  Not only did you have a bike rise from the ashes, but you fixed junior.

If this same thing happened to me, I would have probably called it a "blown engine", sold it on CL as a "parts bike", and bought a new one. 

[adidasguy]

Congrats!

Thank you for getting things started. It really got me going when you helped take apart Juniors bad engine. Too bad you weren't available to help with the transplant.

I got Junior cleaned up tonight. Still a little to do getting all the parts back on (belly pan, hugger, etc.). I did get him on the street. Rides much MUCH quieter than before. Occasional run-away throttle. That can be dealt with. I'll re-check everything after another 50 miles or so. I think everything needs to get used to running. It may have been 2 years since the engine bottom ran. Runs smooth and shifts really nice.

[adidasguy]

I hope everyone clicked the link to see the video.

Here it is again:

http://youtu.be/9GJvzwadV18

[Big Rich]

That's awesome news Adidas - congrats!

[bryan88]

Well done man!

[adidasguy]

And Junior says "I'm Back!"

Junior got cleaned up. Posed for pictures then took a test ride on Vashon Island.
(Sorry to people expecting parts: I had to ride today rather than pack parts. They'll be a day late. I hope you understand.)

A different look without the belly pan. I like it. It may go back on in a week or so. I left it off to look for oil leaks and be able to get exhaust off when I recheck everything after a tank of gas (you know, head bolt torque, valves, etc.) I figure this "frankenstein" engine needs to go through a normal new engine break-in for all parts to work together.

Thanks again, guys, for all your help.     

He runs well. Never had to adjust the clutch. Just put the clutch cover back on as before and it works perfect! I miss the cam shaft clatter (aka counter balance bearing going out clanking  ). Now I can hear what the exhaust really sounds like! Sweet!

[yamahonkawazuki]

The clutch worked fine. The engine ran with normal power. The funny sounds when hand turning the engine appeared to come from the rear - transmission area. Engine actually turns real nice by hand. Very smooth operation.

When cranked by hand, it was normal. I did a small crank backwards to get the piston at the bottom to see with the spy cam. That's when I hear this unusual grinding/scraping sound from the tranny area.

More I am thinking the transmission. It started at a down shift at high RPM. Bike ran all the way home. Started fine at the ferry and after the ferry ride. No loss of power, no stalling, no smoke. Normal idling.

Just this incredibly loud clacking, banging and metal hitting metal sound. It kept getting worse as I got closer to home.

Interesting that a look inside the cylinders with a spy cam shows nice, clean pistons. No metal fragments or debris in them at all. If the engine blew a valve, wouldn't there be loss of power or smoke? Wouldn't I see odd stuff when peering through the spark plug hole with the spy cam?

Thinking about it and that it happened on a down shift with no loss of engine power or acceleration, me thinks I am gonna hafta crack open the motor. I do have 2 1989 engines with good bottom ends and low compression. I can take the tran out of one of those (one has that bad pin for the timing thingy - good candidate to cannibalize).

I want to take a break but I am so tempted to pull the engine and crack it open. Anybody want to help?

Any more thoughts on this?

I guess I could disassemble Junior and do a total clean-up. Maybe rewire with a 2006+ harness and switch to newer carbs? I'll clean up an area of the Cave for Junior's parts.

dig thru trans. problem lies there i believe, check the shifter dogs. ( shifter forks among other things, something in there is amiss