SV650 Motor Build

[daviid]

Here is a teaser










Crank Walk Spacer Plate

[Cerberus]

i thought the heads were ready?
you're going to have to clearance the cam to bucket with appropriate shims.. that is a bit of a process.. and that is totally independent of valve to piston clearancing check and piston to head clearance check

[daviid]

i have all that on a peice of paper where each shim is supposed to go. better to package them up then risk losing tiny parts like that in shipping

[KB]

You sir are out of your frikin mind.

KB

[brewmaster]

Mmmm shiny parts!!!!

[daviid]

Note: All bearing clearances were checked by the machine shop that performed the machine work on my engine
First start off by splitting the cases. First I installed both of the transmission gears. Followed by the shift drum. After install the shift drum, I placed the shift arms in the correct spot and lined them upto the shift drum. When in the right spot, I slid the shift arm rod into place and “locking” the arms into place. I also put assembly lube on the ends of each gear assembly and shift drum

Next slide in the crank and make sure that the rods go through the correct cylinder bores

Next take SuzukiBond (or its equivalent, I could only get Yamabond) and put a thin layer around one of the case halves. Make sure not to block any oil holes. Wait about 1 minute and slide the cases together.


Use the 4 long 5mm allen bolts on the stator side and torque them to 26Nm
Flip over to the other side and use the 3 medium length 5mm allen bolts and torque them to 26Nm. The remaining 8mm hex bolts get torque to 11Nm.
Next I put the engine on the engine stand I built

Here I replaced the output shaft seal and placed the spacer back on

Here is the Gear shift indicator in place



Now go to the stator side of the motor and install the timing chain

Next install the cam chain tensioner. It will be Bolt, CCT, Washer, Motor. And torque to 10Nm.


Now install the starter drive gear

Then install the Stator/Flywheel. Make sure the crankshaft is dry and the key is in place. Torque to 120Nm

Now flip to the other side and install the cam chain drive sprocket. Make sure the 2 dots are aligned. And install the cam chain and tensioner as well.



Next install the main drive gear. This bolt is a left hand thread and needs to be torque to 70Nm


Next install the shift star and detent. The detent is torque to 10Nm and the star is 13Nm

Next install the gear shaft arm. Make sure the spring sits over the bronze fitting



Next install the oil pump. It is 3 screws. Make sure the pin is placed on the drive shaft. Slide the gear on top and replace the circlip.


Next install the starter gear and shaft

Next install the starter.

You can now put a new gasket on the stator cover and install it

Next install the piston rings onto the pistons. First place the Oil Ring Expander into the bottom groove. Make sure the ends do not overlap and are butted. The end of the ring should be 90* off of the wrist pin. The Oil Rail Rings (Very thin rings) will then fit on the top and bottom of the Oil Ring Expander ring. Make sure the gaps are 90* away from the expander gap and away from each other. Wiseco sent a bronze colored ring and a black colored ring each with a number on them. The black ring is your 2nd Ring. Install this with the numbers facing up. The same goes with the Bronze ring. Make these gaps along the wrist pin and each one of the 2 main rings facing away from each other (ie Top ring facing east and 2nd ring facing west).

Next install 1 circlip into the piston, I then used some assembly lube and coated the journals of the piston and inside the connecting rod. Install the piston so that the arrow is facing the exhaust (right in front of the small valve reliefs)

[OreoGaborio]

You sir are out of your frikin mind.

KB

[BMFR6]

lol.
makes me happy i only have to tackle this on a two stroke.

[Cerberus]

looks fun to me..
but the circlip on the oil pump drive gear doesn't look like it is full seated into the groove..

[scottieducati]

At least it goes w/ your paint scheme That's gonna be one sick Yammizuki 650

Next take SuzukiBond (or its equivalent, I could only get Yamabond) and put a thin layer around one of the case halves. Make sure not to block any oil holes. Wait about 1 minute and slide the cases together.

[daviid]

At least it goes w/ your paint scheme That's gonna be one sick Yammizuki 650

You sir are going to be kicked in the nads the next time i see you