Can you feel any deep scratches with a finger nail?If not they should be good for honing.The pistons maybe salvageable.Then you'll only need gaskets and rings.

Those were pictures from the seller, I haven't bid on the cylinders or pistons.

Quote from: utgunslinger13 on June 16, 2008, 07:54:48 PM
Those were pictures from the seller, I haven't bid on the cylinders or pistons.

Ahh.I thought that was your cylinders cleaned up.

Those appear to be in good shape.Honing will take any light surface damage off.

yo, i may have a motor for you ut

ive got a spare motor here, i got from the guy on the forum a few months ago, a rolling project, i have to test it out anyhow, so ill hook all my stuff up to it SOON and see how well it runs, and i just got a line on a project bike and another motor thats said to run. pm me your number well talk. anyone else looking for a motor hit me up i may just part some projects since there is so much demand.

Quote from: ben2go on June 16, 2008, 11:30:39 PM

Ahh.I thought that was your cylinders cleaned up.

Those appear to be in good shape.Honing will take any light surface damage off.

Thats what I thought but figured I would get some other oppinions since everyone has been so helpful so far!

Quote from: cd on June 17, 2008, 12:54:03 AM
yo, i may have a motor for you ut

ive got a spare motor here, i got from the guy on the forum a few months ago, a rolling project, i have to test it out anyhow, so ill hook all my stuff up to it SOON and see how well it runs, and i just got a line on a project bike and another motor thats said to run. pm me your number well talk. anyone else looking for a motor hit me up i may just part some projects since there is so much demand.

I might not need that motor just yet, let me talk with the machine shop I've been speaking with and see what they say about my cylinders!  I am trying to find time to drop it off with the machinist before work this week but hasn't happened yet!  If it comes down to it, I would love the new engine but not yet!

Thank you!

First of all, very nice work so far on the teardown and diagnosis.  If I were you I would wait until your service manual comes and use the specs and testing procedures to check every tolerance on both the top and bottom end.  You can grab a cheap digital caliper set for <$20 to take your measurements. 

IMO, that cylinder is scrap.  I agree that replacing it with a good used piece is your best bet.  The one you posted above looks very nice.  Your cylinder head looks fine, just be sure to de-carbonize the combustion chamber as best you can.  You may be able to get away with re-using those pistons; it depends on how they measure out compared to the spec.  Examine them very, very closely for any signs of pitting or gouging.  If they're not perfectly smooth they're trash. 

You'll need new rings, wrist pins and circlips for sure.  That's about $100 total I believe.  You'll also want to hone the new cylinder before re-installing it.  You can borrow the hone from AutoZone, PepBoys, etc.  Bring along your electric drill and you can do it right there in the parking lot. 

Be very, very careful when re-installing the cams and go ahead and check your valve lash while you're in there.  Check, double check, and triple check to make sure the timing is set correctly or you'll have bigger problems to deal with.  The manual will walk you through this. 

Finally, you'll need a helper to get the engine back into the frame.  It was the hardest part of the job for me. 

Thanks for the comments and input!  I have found a machinst that is going to look at my current cylinders to see how far out of specs we are looking.  It looks like I'm going to spend about the same money if I buy cylinders with a rehone and pistons, as I would for an overbore and oversized pistons so I'm going to see if he thinks my cylinder is worth saving.

If the machinst feels it can be saved with a .5 overbore, then I'm going with oversized pistons and the overbore. But if he feels that he can't save it with an overbore I'm going to pick up those cylinders off ebay and rehone with my stock pistons.  I just can't do anything till I can find some time to drop it off at the machine shop and have him work on it.

Let me know if you agree with my thinking here or if I'm missing something completely.

Thanks,

Nick

I couldnt agree with your decision more  All the tolerances and service limits are quoted in the Factory service manual, I have posted what I think are the relevent ones further back but ask if you need any others and I will look them up for you..........dont forget the gasket set 

Quote from: utgunslinger13 on June 17, 2008, 12:29:35 PM
Thanks for the comments and input!  I have found a machinst that is going to look at my current cylinders to see how far out of specs we are looking.  It looks like I'm going to spend about the same money if I buy cylinders with a rehone and pistons, as I would for an overbore and oversized pistons so I'm going to see if he thinks my cylinder is worth saving.

If the machinst feels it can be saved with a .5 overbore, then I'm going with oversized pistons and the overbore. But if he feels that he can't save it with an overbore I'm going to pick up those cylinders off ebay and rehone with my stock pistons.  I just can't do anything till I can find some time to drop it off at the machine shop and have him work on it.

Let me know if you agree with my thinking here or if I'm missing something completely.

Thanks,

Nick

Now get those cylinders to the shop already... we want to know how this story ends!

I have purchased the manual from the link to amazon on the homepage, and I would like to wait till thats delivered before I drop the cylinders off at the shop so he has the manual with him for specs. However, amazon said I won't get it till the 23rd!!!!!  I'm not sure if I can wait that long, and I might just ask for a big favor and have someone scan or type up everything he might need for specs so I can drop them off tomorrow morning!

I picked up a complete gasket set from ebay along with a new tachometer cable.  I have to keep myself focused on the engine for now so I'm not jumping all around with different parts/projects on the bike, there is so much I want to start working on!  But I just keep telling myself, engine first. Get it running, then worry about everything else.

Quote from: utgunslinger13 on June 17, 2008, 12:29:35 PM
Thanks for the comments and input!  I have found a machinst that is going to look at my current cylinders to see how far out of specs we are looking.  It looks like I'm going to spend about the same money if I buy cylinders with a rehone and pistons, as I would for an overbore and oversized pistons so I'm going to see if he thinks my cylinder is worth saving.

If the machinst feels it can be saved with a .5 overbore, then I'm going with oversized pistons and the overbore. But if he feels that he can't save it with an overbore I'm going to pick up those cylinders off ebay and rehone with my stock pistons.  I just can't do anything till I can find some time to drop it off at the machine shop and have him work on it.

Let me know if you agree with my thinking here or if I'm missing something completely.

Thanks,

Nick

Good plan of attack.I think you will have a long lasting engine this way.

Quote from: utgunslinger13 on June 17, 2008, 03:52:17 PM
I might just ask for a big favor and have someone scan or type up everything he might need for specs so I can drop them off tomorrow morning!

Well, alright... but only if it will get you to the rebuild faster:

Quote
But I just keep telling myself, engine first. Get it running, then worry about everything else.

Agreed! 

Reading that makes me realize I will never know enough about engines, this thing is like giberish to me!  But I'm printing it out, and taking everything to him tomorrow morning!  He agreed to inspect it for free too!

  hey my engine just went too.  this would be the second motor now ..    siezed at the light  heard slapping i think but the pistons look to be in the right spots .and the valves do too .   oboy i guess i have to dig in to it... 

Good Luck!  Its a fun job if you have the room/tools/time, which I have none!  I'm not a genious in any stretch of the imagination but if you have any questions feel free to ask and I'll see if I can help!

Thanks,

Nick

For people that are rebuilding your engins you might want to consider taking an auto shop class at your local high / tech school and that could be your project since they both are 4 stroke engins. -- best of luck JIM

I guess I've had a little practice. I worked at a shop for 3 years in highschool, and I've built or help build countless turbo projects on cars. But honestly, with a little patience and ALOT OF HELP FROM GSTWINS.COM you can learn to do anything.

Nick

I was an auto mechanic for years and had to relearn every thing to work on MC's.They're a bit more complicated and the carbs are very different.

Yeah, I know that the carbs are going to be a complete different story.  Once I get the engine back together, which will be a learning experience as is, I'm a little nervous to learn the carbs. But its not going to stop there. I want to repaint the frame, so I need to learn the disassemble the forks and the rear tire mount and swing arm.  At least by that time I'll have my manual and should ***HOPEFULLY*** be clear how to procede.

BTW Spell check gave an error, so I apologize if there are some bad spelling mistakes!

I dropped the cylinders off at the machine shop this morning, and he said it didn't look like a hone would clean up the damage.  He is going to try and then call me later today.  He said he also might have a line on oversized pistons for cheaper than the Suzuki parts.  So if things go well I should be able to get it back within a week!

I'm just curious as to how the reassmbly will go with the rods still attached to the crank?  Any time I've seen an engine reassmbled, the pistons and rods are put into the cylinders then tightened on the crank?  Any suggestions?