Haha that would be realy cool indeed.
Maybe i will use the engine that will be left over after this engine swap in a full engine revision/turbo projekt later.

Today i got a phonecall from the Suzuki dealer:

Time to play.

Quote from: dB-tje on December 03, 2013, 12:21:18 PM
Today i got a phonecall from the Suzuki dealer:

Time to play.

Nice! Looks like fun   

Excellent job Dirk! As a tool and die maker, I can appreciate your effort as well as craftsmanship! 

Thnx guys.
Yesterday i started taking the engine appart.
First i started splitting engine and found out that the beg end bearings were not that bad at all actualy there was no visual wear at all.
After that i took the head of i found out that the exhoust valve was not on time .
Here a view pictures:




Note the scratch in the last picture.

I think i can better put some work in my old engine in stead of using this one.
What do you think?

That "dent" in the pistons is normal. It is a depression for the exhaust valves to open up.
The scratches on the cylinder wall are also quite common. You can hone them out and put in new piston rings.
So what did you think was wrong with that motor?

I thought the big end bearings were damaged but i can't see anything on them :-/
When the engine was rotating there was a loud knock on every turn.

With the head off, does it knock when cranking the motor?
Maybe just the timing was off or a halve was tight or sticky.
Need more information to help diagnose the problem.

Quote from: adidasguy on December 17, 2013, 02:28:06 PM
With the head off, does it knock when cranking the motor?
Maybe just the timing was off or a halve was tight or sticky.
Need more information to help diagnose the problem.

Thanks adidasguy, i right now is is not possible to check valve clearance
I know that the exhaust valve was one tooth off on the chain, but on the valve or pistons there were no marks of both touching each other.

The knock in the engine could only be heard when using throttle, not when driving at constant speed or stationair.

Here a view more pictures:

And than it was reboulding time: a view pictures:  *O*

Awesome photos mang!! Love seeing the exploded view of the bottom ends. Great progress so far!

Thnx

Today i adjusted the valve clearence. When i started they were 3x0.11 and 1x0.15mm (spec 0.03-0.08), now all are between 0.05 and 0.06 with is quite PERFECT!
i also mounted the valve cover so now the engine is ready to be instaled to the frame again. Can't wait to here it run!!! Fingers crossed.

Quite a project. I haven't had the guts to crack open a motor yet.
Any that I've tossed out were a real pain to open to sort the metal for the scrap yard.

Quote from: adidasguy on January 02, 2014, 12:12:01 PM
Quite a project. I haven't had the guts to crack open a motor yet.
Any that I've tossed out were a real pain to open to sort the metal for the scrap yard.

This is the third engine i opened, the first was only for a new gearbox the other one is still in parts on my desk.
Opening then is pretty easy, just make sure all the bolts are out, the first time i forgot the one that's in the starter compartment (the only bolt that mount the two parts from above). when all bolts are removed i use a 1/4" (wrench) screwdriver to pop the two halves on the front and the back.

Totday i mounted the engine back to the gs500 frame
So it was time for the first run after reboulding the engine.

http://www.youtube.com/watch?v=xaGM2JVHmF4

Now i know it runs Well, iTS time for Some clearingbank and the build-off.

Sounds great!

Today i worked on the bike a view hours, this is the result:


Sadly there is also some bad news, the left carb is leaks petrol through the air filter
So i need to do some more hobbying  

Bravo.

This bike is still as sekc as all hell man... Great job.

Some suggestions if I may say, rim tape, aftermarket pegs, SS colored lines etc etc? Even though it doesnt need em I think it would look awesome.

You did a nice job.
Congrats!