1999 Suzuki DS80X

[velociraptor]

I found a motion pro...I mixed the name up .

 

[velociraptor]

No oil pump that's been long bypassed I stick to premix as I've had an oil pump quit mid ride before something that vital relying on even more things to fail plus it just runs more consistant.

 

[velociraptor]

For future reference br7es 18-21 ft/lbs .032" gap

 

[my67xr]

The 96 and on DS80 use the resistor plug, so does that mean you have a non resistor spark plug cap ?
When you unscrew it from the coil lead and measure the resistance across the cap you get 0 ?

 

[velociraptor]

It's a basic coil of steel under a rubber cover for a cap on it no resistor here

 

[velociraptor]

Read this while at work and in a hurry lol I got what you were saying now I can read lol. Yeah it's non resistor cap with resistor plug but say I ever decide to try a resistor cap and non resistor plug I have plenty of em from Honda projects ect.

 

[velociraptor]

ok so I rejetted the pilot jet right from mikuni and gave the engine a lil more air to breath the results are massively different had smooth power along with pulling out of a turn like a bull

 

[velociraptor]

Still a bit to go but she's riding good. Next up is new throttle cable I believe it's grey some new hardware a good cleaning and a touch of color along with some small stuff until my next splurge which may be a few things including a fmf tuned pipe headlight bulbs tail light switches front brake lever.......yeah I really need that lol I'm prob gonna get a uni

 

[velociraptor]

Wellllllll......I got a bit to wondering about a lean spot I keep having every now and then so I Checked out the crank seals ect needless to say engine is 100%disassembled on one of my shop tables inspected bearings ect as well found out of tolerance left crank bearing. Now it's waiting for new crank seals bearings and gasket material.

 

[velociraptor]

If anyone needs a pulled apart view of an engine lol let me know

 

[my67xr]

If you get a chance, cb750mike was looking for a how remove/replace the DS80 kick start shaft tutorial :bolt:

http://www.miniriders.com/japanese-mini-s/41541-questions-about-my-1996-ds80.html

 

[velociraptor]

Lol idk if I helped or not but I tried. Got my new parts coming in waiting on three things and I'm back rebuilding it

 

[velociraptor]

Ok does anyone happen to know the tolerances for the ds80 crankshaft bearings? I know there is a tolerance of a lil play ect but each engine is unique on how much

 

[velociraptor]

Well got some work done my one day off from my new job and got the crank bearing bearing seal installed and even cleaned the crank up as it had some rough spots that were creating friction

frozen the bearing heated the case and tapped it right in

 

[velociraptor]

Ok got a hold of copper gasket sealant permatex grey installed the new crank bearings seals ect. I may actually get a second to put it together . Hey xr do you know the torque for the crankcase bolts?

 

[my67xr]

Here is the Suzuki pdf, it has the torque setting's etc
Specifications Bulletins 1 - 5
http://www.ozebook.com/compendium/techbuls/SerBulletin Specifications 1-5.pdf

Down below it there is a DS80T file that has some spec's too.

Don't look at the scan's for too long, you'll get a sore neck, lol

 

[velociraptor]

Thanks Craig. Got a new job and TIRED. Lol this is my one weekend to do this

 

[velociraptor]

Ook I'm gonna guess and say clutch hub torque is 18-19 ft lbs?

 

[my67xr]

Yeah i'm not sure, i haven't torqued up anything to factory spec's.
I just do it up to what seems right, then if it leak's i'll do it up a little tighter, lol

 

[velociraptor]

I do stuff like this to spec usually the higher end of scale as to prevent loosening and slipping/stripping I have it now. What I found also is to tighten head nuts a week after assembly as they may loosen as gaskets seat also if tightened when hot even maybe hour after riding gasket will distend into firing chamber creating an annoying TAPPING sound from the piston.....I found my issue