She might be dead

[supersquid]

For the past month my baby has been burning oil like its going out of style (to the rate of like a quart every 100 miles) and I read that I would need to tighten the bolts on the head because it might be leaking oil there. There was a little bit of oil residue so I tighten them up to factory torque specs and hoped for the best. She let burning oil, and now on my way to school she started dying when I'd give her gas. It ended up taking almost 20 minutes to go a mile and a half in no traffic ( usually a 5 minute skip and jump) because I was limited by when she'd go and when she wouldn't. Are these any problems any of y'all have experienced? Is she a project bike now or would a rebuild be in order?

[jonathan180iq]

To burn that much oil that quickly indicates something is very wrong. You must have been like a bluish/gray fog machine driving down the road... Are there not oil puddles under the bike everywhere you park? If there was seepage or a leak, you should have seen it. If it's burning oil through the exhaust, and at that rate, then you have no choice than to rebuild it...

Check and see if your air box is full of oil. There is a drain plug at the bottom of a long hose that sticks out underneath the bike.

[supersquid]

I haven't noticed leaking oil, but I could start putting newspaper under it. It usually rides pretty good but this morning it just ran super rough like that. I need it to get to class everyday so I'm not looking forward to having to do a rebuild. I'll check the air box for oil when I get out of class. How much will a rebuild kit run me if I have to get one?

[jonathan180iq]

When you pull that plug, it's possible that a whole crap load of oil will come oozing out of it.
Let's check that first and go from there.

[jonathan180iq]

Another question. Are you sure you're checking the oil level right and you aren't overfilling? You know to check the sight glass with the bike sitting level, right?

Well... even if you were checking the sight glass with the bike on the kickstand, that would fool you into thinking the bike was full of oil when it actually wasnt... So never mind.

[supersquid]

I just opened the air filter box and there is oil residue at the bottom of it. Not a puddle, but enough down there to cause concern

[raul10141964]

change valve stem seals and piston rings
can be don in one day, not ned to remove the engine from the bike

[Water Warrior 2]

Another question. Are you sure you're checking the oil level right and you aren't overfilling? You know to check the sight glass with the bike sitting level, right?

Well... even if you were checking the sight glass with the bike on the kickstand, that would fool you into thinking the bike was full of oil when it actually wasnt... So never mind.
You just had a senior moment Jonathan. Checking the oil level with the bike on the side stand will show a low level. Topping it up to show a full level will actually overfill it. Oil should always be checked with the bike upright. Just wanted to clear that up.

[supersquid]

Raul, what all do i need in the parts department on that? I'm not a super mechanic but am mechanically inclined so I know between the forum and YouTube I could do that in a weekend. I just need to hop on amazon and order the stuff so I can block out a weekend and have a little too much fun

[jonathan180iq]

Another question. Are you sure you're checking the oil level right and you aren't overfilling? You know to check the sight glass with the bike sitting level, right?

Well... even if you were checking the sight glass with the bike on the kickstand, that would fool you into thinking the bike was full of oil when it actually wasnt... So never mind.
You just had a senior moment Jonathan. Checking the oil level with the bike on the side stand will show a low level. Topping it up to show a full level will actually overfill it. Oil should always be checked with the bike upright. Just wanted to clear that up.

Which side is the sight glass on again?...Thanks for clearing that up. It's been a long time. I'm shopping again, though. Anyway...
God, I can't go around giving bad advice. I'll ruin my good name!

[Water Warrior 2]

Sight glass is on the righthand side. :lol:

[raul10141964]

head gasket
valve stem seals
piston ring set
cylinder base gasket

[jonathan180iq]

Sight glass is on the righthand side. :lol:

That makes sense.

http://cbswwfs.files.wordpress.com/2010/08/bone-head.jpg?w=384&h=229

Raul is giving you sound advice. If it's not visibly leaking out and leaving spots everywhere, it's getting past the seals and rings and burning out the exhaust. You don't have a choice than to rebuild unless you want to just keep adding oil every day until you replace the bike... But that's not the best idea.

[OldNTired]

Sight glass is on the righthand side. :lol:

Of course it is,
how could you look at it if it was on the wrong side? :)

[Water Warrior 2]

Smartypants. :2tup:

[supersquid]

Is valve guide another name for valve stem seals? I'm trying to order parts off of cheapcycleparts.com and their terms reguarding valves is a little crazy and I'd hate to fix something that isn't broken and not fix what is

[blaine]

Is valve guide another name for valve stem seals? I'm trying to order parts off of cheapcycleparts.com and their terms reguarding valves is a little crazy and I'd hate to fix something that isn't broken and not fix what is
No.Valve guides are what the stem comes up through.The valve stem seals go over the stem of the valve & keep oil from going down the guide into the combustion chamber.They are what you want to replace.
:) :cool:

[supersquid]

http://www.cheapcycleparts.com/model_ye ... inder-head (http://www.cheapcycleparts.com/model_years/3802-suzuki-2001--gz250/assemblies/117461-cylinder-head)
Are you able to help me distinguish which that is? is it number 14?

[blaine]

Are you able to help me distinguish which that is? is it number 14?

Number 4 is the valve seal. :cool: :)

[supersquid]

Thank a bunch guys. All parts are ordered and I hope to be able to crank this project out next weekend. As much as I love the sketchy people on the bus, I love the space and babe effect the good old gz provides riding to class

[raul10141964]

On this page
http://www.cheapcycleparts.com/model_ye ... haft-valve (http://www.cheapcycleparts.com/model_years/3802-suzuki-2001--gz250/assemblies/117513-cam-shaft-valve)
#25

[blaine]

On this page
http://www.cheapcycleparts.com/model_ye ... haft-valve (http://www.cheapcycleparts.com/model_years/3802-suzuki-2001--gz250/assemblies/117513-cam-shaft-valve)
#25
It is also a valve seal. :cool:

[supersquid]

Okay, I got the parts in (ordered online and didn't have to wait for a 5th grader to make them in Japan, they had them in stock) and I started reading the service manual on how to do the rebuild. I read a forum post about not having to remove the engine in order to do a top end rebuild, but what are y'all's thoughts about that? The service manual says to remove it. Also, any advise on the Piston pin puller tool? The manual says to get one but I know there are lots of little tricks to get around having to use the tools service manuals recommend.

[OldNTired]

Okay, I got the parts in (ordered online and didn't have to wait for a 5th grader to make them in Japan, they had them in stock) and I started reading the service manual on how to do the rebuild. I read a forum post about not having to remove the engine in order to do a top end rebuild, but what are y'all's thoughts about that? The service manual says to remove it. Also, any advise on the Piston pin puller tool? The manual says to get one but I know there are lots of little tricks to get around having to use the tools service manuals recommend.


No. there is no need to pull the engine for a top-end rebuild.
But a warning: label the bolts when you take them out of the head cover and head. Don't ask why, just believe that I know. :)
As for the piston pin puller, I don't know for sure as I didn't remover mine.
But, I've never used one on any other engine I've worked on.
I'm sure someone here will know, if there is something different about this one.

[supersquid]

After thinking about it, I don't really have a need to pull the piston if all I have to do is replace the o rings once I get the cylinder sleeve off. Also, did you have to get the sleeve re-honed? I haven't started taking things apart for the day but my biggest worry is having to get machine shop work done on it when I'm working on a saturday.

[JWR]

I would think the cylinder should be OK.

[supersquid]

Okay thanks!! Hopefully I'll be back on the roads by tonight. Also, for the timing chain, do you just take the gear off at the top or do you use a chain link extraction tool? The manual was very vague about it

[OldNTired]

Okay thanks!! Hopefully I'll be back on the roads by tonight. Also, for the timing chain, do you just take the gear off at the top or do you use a chain link extraction tool? The manual was very vague about it

You can just unbolt the cam (etc) and remove the cam to get the chain off. Just be
CAREFUL NOT to let the chain fall into the case. I used a plastic tie to hold it up
so it didn't fall in.

[supersquid]

I have it apart and followed the manual available on the first page of the forum. It's currently totally disassembled and in the living room of my apartment (my landlord made me take the engine out instead of doing it on the bike). I keep trying to find the gasket for where the valve cover and the head meet. I ordered the gaskets that someone mentioned on the other page but now that I have the engine apart I realize something needs to go there. Do I just use the gasket in a can type of stuff? The old gasket that pealed out of there wasn't the paper style as the cylinder base gasket was, but rather rubbery

[OldNTired]

I have it apart and followed the manual available on the first page of the forum. It's currently totally disassembled and in the living room of my apartment (my landlord made me take the engine out instead of doing it on the bike). I keep trying to find the gasket for where the valve cover and the head meet. I ordered the gaskets that someone mentioned on the other page but now that I have the engine apart I realize something needs to go there. Do I just use the gasket in a can type of stuff? The old gasket that pealed out of there wasn't the paper style as the cylinder base gasket was, but rather rubbery

There is no gasket that belongs there. Use a high=temp sealant. I used Hylomar Blue.

[supersquid]

Thanks!!! Hopefully I can get the engine back together soon