GS550 Build Episode 6 - Engine Assembly

what's happening people I figured I better get back in this garage and continue to work on the bike here you can see behind if I don't kill myself I [Music] got some my cylinder Bank here sort of done some honing on the cylinders got to clean them out there I got new rings put on the Pistons I cleaned up the pistons and threw some new rings on them so I got new snap rings and everything so we're gonna start with the engine assembly to get this thing back together there's some engine paint touch-up that needs to be done but I'm not gonna worry about that until it's all back together what we're really gonna concentrate on is getting the Pistons back onto the con rods get the wrist pins in there get some assembly lube on but the snap rings back on keep them in place and and then we're going to try to get the piston bank back on there we'll see if I can pull it off without going to get one of those piston ring compressors I've got to clock these rings they're just kind of on there right now the book spec shows you you can see in this image here that there's a certain way that you need to clock those rings so I'm going to try to get those things set up as close as possible before I put them on the con rods they'll probably move a little bit not terribly worried about it I'll check it again before I try to get the cylinder Bank on and then I envision some sort of a wrestling match where I'm trying to figure out how to get these things back into the Pistons without a piston ring compressor we'll see how it goes and maybe it may mean that I need to pause and go and get more tools but we'll see how it works out what else are we doing today if we get that far and I can actually get this Bank back on I'll put the head back on put the cylinder head back on I got new shims so we can adjust the valve so I got there clearances recorded and everything so we'll put the shims in there we'll get the cams put back on set the timing and get the whole top button back up that's the goal I don't know if it'll be done today or if this is gonna bleed into another day maybe tomorrow but we'll see so we're gonna jump right into it and start putting the engine back together [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] [Applause] [Music] [Music] so the idea here is that for each of these pistons to make it easy on myself I'm going to start with the middle and work out so this is piston I marked them just piston number two has a little arrow on it to tell you which way is forward so I'm gonna get this connected get the snap ring in so this piston isn't in the way and then I'll come over here turn the crank get this one up put that one in same thing on the other side I'll start in the middle get this piston connect it and then work to the outside again that way I'm just trying to leave myself as much room as possible while I'm in here trying to get it get everything reassembled [Music] [Applause] [Music] [Music] [Applause] [Music] [Music] [Music] all right so you can see that the cylinders or the Pistons are installed on the connecting rods here and so I'm ready to try to slide the cylinder bank down on top of these Pistons again they're kind of floppy all over the place as you can see right now nothing's holding them stable nothing is holding them in place and so I'm gonna try to use this little diagram from the book and what the book says is to basically take some take some wood blocks and I have a couple of scraps here and basically just create these spacers and these kind of like hold up spacers and what what what the intention is is that you get those spacers in place and they'll sort of sit underneath these Pistons like that and hold them in place while you try to slide the cylinder Bank down on top of it you crank this around and it'll give it'll give it something firm to sit on top of and they won't move I don't have a piston ring compressor and so I'm going to try to do this with my fingers and see if I can finagle it if not I'll go to the auto parts store they sell piston ring compressors or even like a decent-sized hose clamp or do the tricks since these pistons are so small so so I'm going to do a little bit of woodworking just probably chop these up roughly with a with a jigsaw not gonna take too much time here one of the idea is to keep the progress moving on the engine and not make some pretty wood things so here we go we're gonna give it a shot [Music] [Applause] [Music] so you can see here that I was able to get the cylinder Bank on top of the cylinders without using a ring compressor or a hose clamp so that sort of worked out the bottom of the cylinder banks were kind of fluted so they kind of helped the reins go up in the cylinders [Music] [Music] [Music] [Music] [Music] [Music] so I saw this egg carton trick from another youtuber a while back I can't remember who it was but it was just an easy way to keep all the valve tappets and in order so that they went back into the valves that they came out of I didn't want to mix them up I really don't know if that would make any difference but out of an abundance of caution I really wanted to put everything back where it came from the first couple of them they went in they were kind of sticky and so I thought hey let's throw some assembly live on these two and I seem to help out a lot so I went ahead and applied a bunch of assembly Lube to the valve springs there and then also to the tappets themselves and they slid in a lot easier now later on I put some on the face of the valves or the face of the tappets before I put the five shims in there as a way to just both give it a little bit of lubrication and help the shims stick in place so they wouldn't fall out [Music] so here you can see me starting to put the bow shims back in and I'm referencing my notes in my notebook which made it a lot easier so I ordered the shims and they came packaged in these little baggies so I took out each individual size that I need and just placed it on the tappets according to the note I put in the notebook real simple child just put everything in make sure they were in the right places and you can see there my little chart of the whole versus the new [Music] all right so it was hard to get a clear close-up of the little View window there in terms of where I was actually sitting in the timing mark but I essentially had this set four Pistons one in four had to set at the top dead center before I could move on to placing this exhaust cam in the right place so I got that timing mark in the ignition setup turned it over a few times guy really tried to make sure it was really nice and closely marked up how it was supposed to be not set the exhaust cam in I think it was number one was you'll see in that previous clip was pointing towards the front had to line that up then once I got that set to the correct place I was able to put the I guess these cam holders whatever these are called the little clam shells I was able to put those babies in there and get them locked down so that the exhaust cam went move and that can move on to setting up the intake cam [Music] okay so I had to set the exhaust Campbell code into the number one mark on the gear there but you can see here I'm counting these link pins and I think for the GS 550 the one I'm working on here I think it was 20 or 21 link pins back I can't remember off top of my head but I had to keep counting those link pins to make sure that from the number to mark on the exhaust cam to the number three mark on the intake cam it was a 20 or 21 pins whatever it turned out to be if you pause the video you can probably count those for yourself and see what those marks lined up but that's how the book specified to set up the timing for the intake cam [Music] so once I got the cam chain tensioner set in there you can see I tapped on a little bit to see if I get the spring to pop out but what I ended up doing was just turning the kick starter you can see the motor rocking a little bit turn the kick starter and the change sort of snapped in placement the tension was set on it and so I went ahead and tightened up the jam nut and the lock screw or the lock screw and then the jam nut and it was all set to go [Music] so there it is that's the that's the finished product I think it looks pretty good like I said there's some touch-up work to be done on some of the areas for the paint I'll go ahead and do that was really handy to have it on that motor mount work is swing it upside down and everything but so there's a finished product I'm happy with how it turned out if you liked this video go ahead and hit the like button make sure you subscribe so you can stay up to date on future videos that come out and thanks for watching and we'll see you all on the next one [Music]

Channel: Mike Mitchum

Views: 9,361

Keywords: cafe racer, garage built, motorcycle, GS550, Suzuki, bike, vintage, custom, engine, cams, piston rings, hone

Id: NvmI-Dx5l5k

Length: 33min 31sec (2011 seconds)

Published: Wed Jul 31 2019