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Project Suzuki Across Engine Rebuild

Discussion in 'Your 250cc Projects' started by Jethalter, Mar 27, 2019.

  1. Jethalter

    Jethalter Active Member Premium Member

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    Suzuki Across Engine Rebuild - Well partly, New Rings, Cylinder Hone, New Valve Stem Seals, Blasted Cylinder Head, Lapped Valves.

    If anyone of you read my other thread my Suzuki Across suffered low compression, i was putting off a comp test if that was indeed the case and after rebuilding the carbies completely it was one of the only things left and sadly dry i had 70-70-70-70 and wet test i had 100-105-100-140.

    So i thought i'd start a thread here since its now developed into a project and put me back on my other bike that i was building which is a GT550.

    Stripped the top end off the across motor, everything is so tiny so i had to make a new set of valve spring compressors to suit the tiny little across motor, feels like a toy compared to all other engines i've done.

    Anyway here's some pics of the tools. I didn't need them to be super accurate just more smooth and free of any burrs and such so they didn't cause any damage.
    IMG20190327124127.jpg
    IMG20190327124120.jpg

    Stripped the head completely, valve guides check out quite good, a couple have the smallest amount of play that i'm not concerned by. Im an ideal world they would all be perfect but its as close to perfect without spending a hell of a lot.
    IMG20190327192638.jpg
    IMG20190327192745.jpg
    IMG20190327192754.jpg


    One thing i'm a touch unsure of, some of the valve spring seats fell out and have a shim and some others don't have a shim. Anyway i checked here : http://www.mccullochsuzuki.com.au/suziparts.php?y=1996&u=2160&c=36&f=102789
    and if i interpret this correctly, all the exhaust valves have shims and all the inlets don't ??? anyone feel free to comment here.

    Some of the exhaust ports have oily carbon in them, so these will be cleaned up and sorted when the new valve stem seals go in. Pics are Exhaust ports 1 - 4 in order.
    IMG20190327192711.jpg
    IMG20190327192714.jpg
    IMG20190327192730.jpg
    IMG20190327192734.jpg

    I'm gonna be out of action for upto a week coming so trying to get as much done before tomorrow as possible.
     

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  2. Cbuzz

    Cbuzz Well-Known Member Dirty Wheel Club

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    Watching with interest! Let us know where you source your parts from to. I'm sure I'll be referencing this thread in the future :thumb_ups:
     
  3. Jethalter

    Jethalter Active Member Premium Member

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    Piston rings are AHL from china, the brand seems to make quite a few for all different bikes and from what i gather on other forums of people who have used them they have worked just fine. Price difference is $30 a set delivered vs $275 my local suzuki dealer.

    Valve stems are about the same price from china also for a full set of 16, however genuine are in the area of $180 a set.

    The idea is to keep the cost down, its just not worth spending a lot on the bike.
     
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  4. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Coming along nicely, and give it the beans when you get it back together, none of that 'running it in' nonsense.
     
  5. Jethalter

    Jethalter Active Member Premium Member

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    Of course, ain't no holding back.
     
  6. Cbuzz

    Cbuzz Well-Known Member Dirty Wheel Club

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    Yep, the standard suzuki run in procedure for new rings is on first start up hold the revs at 18 grand for 20 minutes.

    This should also be performed without oil so the rings get nice and warm.
     
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  7. Jethalter

    Jethalter Active Member Premium Member

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    Im still unsure about those shims that are meant to be under the exhaust valve spring seats, i only have 5 shims when there should be 8 ???
     
  8. Jethalter

    Jethalter Active Member Premium Member

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    Maybe not that aggressive, i'll do a few laps revving to 10k, when its warmed up varying the rpms so its not at idle warming up, then i'll give it hell.
     
  9. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    It should have a shim under every bucket , are you sure they are not stuck in the buckets themselves ?

    How did you go sourcing a head and base gasket ?
     
  10. Jethalter

    Jethalter Active Member Premium Member

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    hmm really ??? , i'm certainly short then, there was only 5 shims in it. Im not talking about the ones under the buckets, im talking about the ones under the valve spring seats.

    I've got the 16 shims that sit under the buckets / top of the valve stems.
     
    Last edited: Mar 27, 2019
  11. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Those are steel washers as steel springs against an alloy head is a recipe for a bad time.
     
  12. Jethalter

    Jethalter Active Member Premium Member

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    You have the valve spring, then a valve spring seat which is a steel shaped washer, however some of those valve spring seats had a very thin shim under. like in that link i put up for suzuki parts fich, the diagram shows exhaust has it, but not inlet ??
     
  13. Jethalter

    Jethalter Active Member Premium Member

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  14. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Shimming the valve springs allows you to have the correct compressed length.
     
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  15. Jethalter

    Jethalter Active Member Premium Member

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    13 is the valve spring seat, but 14 is the shim im wondering about.

    im taking it as all the exhaust valves have them but the inlets dont ???

    9 is inlet valve, 10 is exhaust valve
     
  16. Jethalter

    Jethalter Active Member Premium Member

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    do you know what the correct valve stem height should be ??? this doesnt seem to be listed in the workshop manual
     
  17. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    The valve springs should all be the same length to give even pressures on the camshaft. Someone (maybe the factory) may have lost a couple but I would be checking that all the springs are the same and using the shims where they are a bit short.
     
  18. Jethalter

    Jethalter Active Member Premium Member

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    So i just measured the valve spring free heights, every spring measure in at 39.00mm +/- 0.05mm. The serviceable limit is 38.3mm
    based on that without doing a spring pressure test (cause i don't have the tools to do so), none of those valves should have shims.

    Anyway that's about all i can do for the next week or so, cant wait to get back into it.
     
  19. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    I thought you were referring to the shins under the bucket , as for the ones you have highlighted. I am not sure
     
  20. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    The Exhaust valve spring seat shim's in the part's list should be used i would think ?
    There are 2x different part number's for them, but the only one's i could find are .5mm shims, part number 09181-10158
    I'm guessing the original shim's from new are .25mm thick ? Part number 06221-10185
    They are there to give you the correct installed spring pressure and spring height, not running them could risk valve bounce at higher rpm's
     
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