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pickles 644 ds; was routine maintenance turned project:S
Topic Started: Feb 27 2012, 10:21 AM (4,689 Views)
pickle3
Earl
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Still at the beginnings, frame nicely coated by fastline powdercoaters Preston. Waiting to get my rear wheel back which is being treated to a new hub, but need to dig deep to fund chain conversion 520 and a new rear disc rotor aswell as the every maintainance schedule thee change.
Also a very mucky carb to rebuild, and swap cylinder head over which I think I got all bits for now. Just not sure if it would be worth renewing piston rings or not.

Just need 2 get my ass into gear :whip:
No excuses now as its not that cold any more
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Marc
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Marquess
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That frames come a long way since I saw it last in that guys garage....who took all the wiring off....Reevo been round again ?
CCM 644,Kent cam,Braking wavy disc and 4pot caliper,Brembo radial m/c etc etc

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Cuz
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God
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You went off the idea of a white frame then Lee,how you getting on with it?
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pickle3
Earl
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Hey yup Cuz! yeah the powder coater tried but couldnt get it white enough, gutted really as thats what I wanted, but probs better off not white though lol with my cleaning schedule :D

:update controls swapped over too Twinwall renthals, rear rim relaced to new hub tyre been fitted at bike shop when delivery of maxxis on thursday! and going to do some brain surgery on me suzi now once i find a manual i can print off:) post some pics up soon :P
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pickle3
Earl
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Hammer an thwack removel of manual engine rotations nut cover caused brown pants moment, thought I cracked side casing open, glad to see it out although more than one piece.

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Piston crown, didn't polish just petrol and rag:


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More soon just trying to find some Suzuki moly-paste :-)
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pickle3
Earl
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Slow progress and missing yet more ideal rideing condirions <_<

Head is now rebuilt and engine inside frame only one tiny scratch on frame from not keeping work area cluttered.
Valve clearance set 0.1 inlet 0.2 ex , Brisk plugs fitted exhaust port polished.

Swingarm bearings and journals cleaned and greased up, shock eyelet rosejoint/heim bearing replaced, new hub laced onto rim with fresh pressa on. Controls swapped onto twinwalls.

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Next is wireing to get my teeth into :(
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bighit
outta here
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if you have not fitted the head back to the barrel yet . green scotchbrite pads are good for cleaning the mating surfaces , thinners will shift the teflon off the surfaces as well as the green scotchbrite. thats what we use at work
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pickle3
Earl
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I used petrol and some old wire wool I had laying about, it broke up quite bad and I got loads of metal fileings inside that I nipped up with a magnet on a stick nest a could. After I fire her up get oil warm and drop with new filter. And plan to run in for 250 miles then recheck valve clearances. But next time will try the scotchbrite thx for tip mate :D
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pickle3
Earl
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I used petrol and some old wire wool I had laying about, it broke up quite bad and I got loads of metal fileings inside that I nipped up with a magnet on a stick nest a could. After I fire her up get oil warm and drop with new filter. And plan to run in for 250 miles then recheck valve clearances. But next time will try the scotchbrite thx for tip could of saved me a lot of hassle plus when I manually turned crank heard slight scratching sound hope my barrel not scored :unsure: :unsure:

Fingas X'd
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bighit
outta here
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pickle3
Jun 3 2012, 10:12 AM
I used petrol and some old wire wool I had laying about, it broke up quite bad and I got loads of metal fileings inside that I nipped up with a magnet on a stick nest a could. After I fire her up get oil warm and drop with new filter. And plan to run in for 250 miles then recheck valve clearances. But next time will try the scotchbrite thx for tip mate :D

it does not harm the ali like wire wool would . we use it at work . small scratches will be fine on air cooled bikes . its the water cooled ones that need a scratch free finish . when we get heads in at work and they have used sand paper or a stanley knife blade and deep scores its an instant skim . some people just rush in and dont think lol
you did give it some thought though . most would just leave the strands of wire wool in there ha ha . seen it with home porting jobs . big bits of ali dust under the valve seats and crushed onto the seat . they then say they dont understand why there is no compression lol


hope it works out for you pickle
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pickle3
Earl
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I used petrol and some old wire wool I had laying about, it broke up quite bad and I got loads of metal fileings inside that I mopped up with a magnet on a stick best a could.
After I fire her up get oil warm and drop with new filter. Intend to run in for 250 miles then recheck valve clearances.
But next time will try the scotchbrite thx for tip could of saved me a lot of hassle plus when I manually turned crank heard slight scratching sound hope my barrel not scored :unsure: :unsure:

Fingas X'd
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pickle3
Earl
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Big bits of cam end C lock washer still in crank somewhere though so gotta change side gaskets I think, thinking of refinishing side cases in bronze and black the barrel down. if barrel scored well will have to k710it :D
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pickle3
Earl
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Well 3 months on from last post, found my carb needed work because of a quick fix way back with metal putty turned bad. Petrol has been leaching it through messing up my spring and diaphragm. Suprised it was still running at all on pretty much one carb as airmix screw was tightened fully on one of carbs
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Parts ordered from ccm/jumptech local Suzuki dealer wanted 70quid for diaphragm cover assy. Twice ccm price :angel: so decided not to support local business and opted for factory direct. could of gambled on a 2nd hand one but paranoia gpt better of me so refurbed mine, treated it to a new 1into2 intake rubber and moved a notch richer on needle a spray of fual injection cleaner and new diaphragm, spring and carb cover.


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Fitted too bike now just have to tidy-up wireing and try to power up the acumen speedo while I save up for the last few body parts needed (side panels and mudguards if I don't fit tail-pod also lights and headlight and handguards to fit twinwalls, brake pads, armoured ront brake hose and lights).


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Gutted I have missed most of summer, should be starting her up fingaz crossed tomorrow


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hursty46
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The Hulk
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Looking really well bud :D
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Like my CCM I'm old, overweight and badly maintained but I can still surprise you by how fast I can move!!
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pickle3
Earl
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Will do when I get some plastics to go with lime green r30 tank, just can't decide between getting blue mudguards or wrapping white ones in lime green carbon vinyl, can only find yz plastics in white,black anord blue :angry:
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whitebuck
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Dazed and confused
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Impressive work there, good to see such a tidy job

Good luck with tracking down those parts

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Ride It Like It's Your Ex G/F
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pickle3
Earl
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She fired up :drinks: very impressed with myself but wasn't without a few calamities before hearing the thumper again after a whole year in bits and changeing over some parts.
After getting cables routed and the essential wireing plugged in(not lights, horn etc). I went to garage for some vpower, with my gerry can. Got a fivers worth and poured into my ds tank and turned on tap oh crap left my drain plugs open petrol all over starter &garage floor. So closed them up and turned back the tap to reserve. Thought to my self will give it 5 mins to fill up carbs went an made a brew and came bk 5 mins latter with warmer hands to find petrol pissing out of header pipe. Not good! Turned off tap again to are where it was coming from, must have sticky floats (need to know remedy for this) and because I set timing when changing over cylinder head, I left at tdc so both valves was open oops another 2quids of petrol all over garage floor. So left tank off as thought it was flooded pressed starter and dum (half turned and) crackley starter sound. I began to doubt my abilillity and thought I got timing wrong and seized up engine. But decided to check for spark got spark plug out and held it to engine, turned over and kasplatt 644centilitres of v power splatted on garage ceiling at extremely high force and an electric shock for me holding sparkplug cap too far from engine oh s**t! Maneged not to drop bike, and then held plug inside a towel before trying again sparks good and almost fired without the secound plug in as flames popped out with starter going. So put plug back in with my last quods worth of fual started up with a little choke and sounded sweet very happy with sound but just laughing at myself, it could have been a Mr Bean sketch lol.


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wR1sty
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King
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:lol: Glad you got her running in the end mate. Sticky floats, well quick fix is to tap the float bowl with a screwdriver handle etc to shake them loose. Mind you they shouldnt just stick if alls well and clean and not worn ;)
If your not on the edge, your taking up too much room
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Monty
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Charlie Big Banana's
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your luck the suzy has a auto decomp, you could have bent the con rod when you hydroliced it,

instead the load went through the slightly open exhaust valve..
Tap base of carbs gently with screwdriver handle to knock floats down
If it aint sharp I can play with it
My Utube Channel, lots of bike vids here. Subscribe if you likehttp://www.youtube.com/user/choppermark?feature=watch

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pickle3
Earl
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Ok will try tapping them thx guys. Now to tidy up wireing, too much of it dangling too close too parts that get hot :-). And wire in tihe acumen :-/
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