SUZUKI 600cc damaged Engine Repair!
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- Опубліковано 29 вер 2024
- In today's video I weld up a hole in my Suzuki gsxr600 engine block and get my crosskart ready to rip.
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I split a cbr 600 like this. I got the bike for $75, it had smashed into something and the front forks were completely caved in--- the sub frame/ seat was mangled. The chain had slapped the case too -- just like yours. I got lucky and all the broken pieces were only on one side of the split case-- so I bought a used half case on ebay for only like $60, and I blueprinted the crank bearings to make sure it was going to have the right clearance-- and it was within spec. So I just threw it all back together, and then I turned it into a Quad, I used the original frame to start with. I rode it for 6 or 8 years out at the "Little Sahara" dunes in Oklahoma (where I live); and I ended up selling it for $1500. lol.. It was still running like a screaming beast when I sold it.... Everyone told me that the case halves would never work, and that you need to have the full pair. But mine worked fine; even though the two case halves were from different bikes.
Still better off buying non damaged cases. regardless of skill cast cases like this can never be repaired correctly things could be warped & once a cast case like this is damaged it will never ever structurally be the same. for a cart engine i probabaly would've done the same thing though if a case was available at the time lool.
@@drewcecato221 meh.. I disagree. The metal can still flex around a little bit-- the bolts pull it all back into shape for the most part- the only place that it's really crucial is at the bearings, and they typically have bolts directly on each side of them; and the rest of it are just ball bearings, which are self contained. After that, all you have to do is be sure that it doesn't leak oil and it's good. I repaired a broken Honda 200x three wheeler once with a beer can and a tube of JB Weld. The hole was about the size of a base ball and even broke across a seam- we just JB Welded across all of it, so that we could never take the side cover off now-- and that motor lasted nearly 10 more years without issues. Ended up selling it -- the guy knew about the damage and that you can't even pull the cover off anymore, but it still ran great, so he bought it. I think you would be surprised at well things will still work -- if you can just stop it from leaking oil.......... For example, in this video -- the guy has already been riding this buggy and his fix is working fine.
@@calholli meh you're wrong lol. I am very ignorant on this stuff (not trying to act for a second that i am not) but im friends with individuals who are most certainly not and this stuff is a lot more complicated than you're giving credit. You cant just vison what you think is going on and then just assume thats how it works😆. For a cart f around engine? Sure id do it if I had to.... for a street bike? Utterly insane and stupid.
@@calholli "the only part that crucial" LOL yea IS THE ENTIRE CASING bro.. thats whats crucial for strength & supporting the rest the engine, and to to my knowledge why once the cast has a massive hole in it its JUNK. Almost as dumb as welding alu frames. Just because nobody dies doesn't mean it had to be like that lool.
@@calholli im not claiming it won't work or even for awhile. I'm saying its a hackeroo repair and its IMPOSSIBLE to make it as it was before structurally. Common knowledge.
Very impressed, you are fearless to dive in and fix it right. Back in the 80’s - 90’s I picked up a couple nice bikes with just this same issue. I considered them both parts bikes as I lacked the skill and resources to fix them right. Both had fixes attempted, silicone and epoxy. So sad. I echo the others that a case saver will help keep this from happening again. You’re building amazing projects, keep it up!
1:30. Get a set of 6-point wrenches and sockets!!!
Great Job Vasily
That was a lot of work buddy 👍 but you know what to do you are a amazing dude super smart guy 👍 buddy 👌 take care buddy and God bless you my friend 🙏
It's such a great feeling, when you bring a broken machine back to life. 😎
You are truly a proffessional welder. Why not weld a reinforcement of high grade alu on the spot instead of JB? Could save you from future mishaps, if the chain jump again?
Damn man, all that time and effort when you could've just mudded it up with JB weld and a beer can... lol good to see it get done right for a change though, being a low mile engine makes it more worth the effort.
WOOHOO she runs..Awesome job.. Keep up the good work..
Awesome tare down and rebuild 🏁😀🔧🔧🔧🔧🔧
What a can of worms! Someone with your skills should have no problem fabricating a steel chain guard to fit between the sprocket and case to prevent that from happening again. Peace. 😊
Whoa, very impressive. All in all how long did it take you to complete the repair?
OMG I'm a motorcycle mechanic (EU) and my heart hurts when you hammer a screwdriver in ALU
Guys i have 10hp waterpump engine. It doenst have gears it has only 1 gear. Can i build something like go kart with that thing ? Will it work with 1 gear if i make gear ratio ?
They got ratchets for stripped bolts .... you could have use them
The reason it happens a lot is the bike is highly sold
Weird ending
Nice work man 👍 Good repair 🙂
Unfortunately when a chain comes off the case usually gets it. Great JOB fixing it!
needs a guard
Dude that was epic how it started right up, congrats man good job...
Something you might to do is build a guard out steel that can go around the sprocket. that way even it bent the guard it would keep chain from punching a hole in the case again. providing you have something to mount it to for extra insurance in the future. the reason there's no gasket between the two halves is because of the crankshaft main journal clearance. it's actually stronger to have the main bearing caps incorporated into the other half of the crankcase. it's the same princeable as having a main bearing cap girdle. and like you said it saves space.
Nice one! Looks like a good repair . Taking that motor apart looked complicated glad it still runs
Damn dude that’s a lotta work for such a small hole. Had no idea that the main caps were part of the lower case. That’s crazy! Ya did good tho man! High five for sure 🙌🏻
I just put new sprockets and chains on my Ducati Monster 620 over the summer. I found out that anything over 250cc is recommended to have a rivet style master link so I ended up buying the appropriate chain and the removal/rivet tool. I'm aware that your chain didn't break but thought I'd share the knowledge. Spectacular job btw, you're a sharp kid.
Good job dude. I don't know if I would have had the balls to tackle that at your age. Bravo.
What was the huge mistake?? Great content keep it coming. 👍🏻👍🏻 maladets
I've been watching you for awhile, your mechanical skills are progressing nicely. Keep at it, patients are a virtue as well as perseverance. Keep up the good work.
Good comment patience is lost in my world
Nothing a little bubble gum can't fix. Great job, bro.
Bud I have to say For a Young Man Your not afraid to tear into anything. Great job on the repair. Alot of people would of been scratching their heads and end up throwing the engine away.So My Hats off to You Sir...It sounds Great..Question can You take a piece of Thin Steal and make like a Guard and put it where you repaired that in case the chain decides to do that again. Like bolt it to one of the other bolts there. Just wondering..Great Job again and Video...
PS, something I learned from racing.. Always use master links that are the same brand as the chain.
I broke 4 chains (while leading ) before I figured it out. 🏁😎👍 no after market links.
GBY and have fun
I cannot imagine even attempting to do this. Very impressive
Now you need to build an overbuilt case saver/ steel guard. It's best if you mount it to your frame, rather than the engine. Because if your chain breaks again, and it slaps your steel guard- it can still break where it bolts to your case. So make it bolt to your STEEL FRAME and make sure it's removable. I wouldn't ride it again without a heavy guard around that chain though.
Dude, not gonna lie. That was pretty badass. Just a couple years ago you weren't even able to turn a corner without hitting a house and now you're rebuilding a pretty technical engine for your custom made buggy. Wtg man.
Colour me impressed. 👍
👍👍👍 круто, я думал обратно его уже не собрать)
I'm impressed! Nice work... I run a sprocket protector/guide on my big sprocket to prevent dropping a chain and punching a hole in the case, I make my own out of high density plastic. I just made a pair today for my new sprocket.
I had whole in 350cc warrior case frome the chain. Jb weld would last a couple hours , oh same whole here its common when you don't maintain chain tension and sprockets ANYWAYS epoxy wouldn't hold due to heat and vibration, what I used was high temp boiler silicone having a little flexibility it lasted forever. # the whole was on the top probably wouldn't worked if been on the bottom
Awesome job Vasily!Glad it had no internal damages,and fired right up.Let 'Er Rip !
If you have a stripped bolt just weld a nut to the bolt and bang u can extract the bolt
What size tube did you use for the chassis? Wall thickness?
Dude I've watched you from day 1 and I'm always impressed with your skill! Awesome job man.
You are very good at what you do! Good job
Fantastic effort...that's a complex engine!!! Great to see it running again.
Sure hope you install a Case saver on her!!
Looks to be lots of room to make one to fit her!
Good job man. For your first time splitting cases you did great. Also A++ on using oem gaskets and torquing all the bolts.
Out of all the Japanese I4 motors Suzuki are by far the easiest to work on. Honda while well engineered are imo the most difficult. I've torn down so many Hayabusa motors that sometimes I literally dream about them.... Lol
Salute You from Arad/Romania!Don't know what to say..Better to welding whit all of parts from crancase in position,whith all the screws,bearings(fake bearings)..Let after to cool in long time,gently....
Nice work,my friend...You are an artist!
Unbelievable that you can do this in your own. Many people can't fix a flat tire 🤪😂. I love it to see your video's.
Cool
This video is still relevant in 2023 i just completed the build after watching the video. For a person with a old dresser as work bench this build wasnt that hard. Took me a little close to 5 hrs start to finish. When removing the parts he doesnt really go over on how to take out. look up another video on youtube and then get back to this video😂. 5 hrs of watching this 10 mins video actually worked 🤷🏽♂️ UA-cam mechanics for winnn🔥
Alright Mr. Wizard! Dude, you are amazing! I could only wish to be this talented man. I couldn't put that engine back together PROPERLY if my life depended on it.
Wow man, glad you got er back together, cant wait to see what this things gunna do with some seat time! Thanks for the video brother its keeping me motivated. That was a complicated rebuild! God bless
Great job with the Suzuki plug. Hope they appreciate that. Let me know if the throw you anything. Lol great job bro. Impressed with every vid. Oh and make sure the chain master link clip is properly in place. I almost cracked the case on my Banshee Cause my dumbass put it backwards, open side facing front when chain was on top of sprokerts Wrong.
Always remember, a man put it together and another man can take it apart and put it back together again. It's just parts and bolts, seems very intimidating at first, but it's really not all that.
Jb weld and a beer can on my old CB750 lasted for 40 years without a leak. spl;itting cases is too much work..lol
I know for dirt bikes you can buy case protectors for that issue. Its a pretty commn issue. Even hapend to my cr250. Maybe you can find one made for that engine?
Eyyy can you come help me work on my 1986 kawasaki eliminator 600? Lol
You should always put a case saver on any chain driven motor engine whatever you want to call them. A case saver is a piece that goes in front of the front sprocket to catch the chain if the chain snaps or pulls the back sprocket forward look up dirt bike ones you'll know what I'm talking about you could easily make them
Great job fixing it. Don't understand why youd fix it so nicely and then make it look like a botch job from the outside tho.
Im impressed, that is one complicated engine. And you used a manual. That is impressive by its self. Well done.
hello, don't you have the full video without cuts? I need to be able to see all the steps shown please! I had the same problem, something more serious... and I'm trying to put it together, but I can't do it
I have done that several times J-B weld will not hold by itself but it can be brazed with screen wire or just bracing it with wire works just fine can actually be made stronger than the original case
I see some cracks under the weld? Is that stretching from heat to cold? Great video and weld ,filling
4th
6.34 sur if you are going to wear 1 condom , 2 condoms aint goint to hurt ,LOL LOL
Damn, impressive young man, you’re not afraid, A+💯
Look into building a "case saver" they are used normally on dirt bikes and such.
1st
Alinhamento incorreto entre o pinhão e a cremalheira. Ou deformação do chassi k provoca isso.
Où puis-je me procurer le livre pédagogique ?
That's another way to hide a weld. How many tig rods were used?
Gsxr 600 dont have balancer shaft like gsxr 750
Great job I got some welding for you on my truck
weld another plate on the outside that will take the chain hits instead of the cast block
U took ur thumb nail picture from my instagram
You are a very good mechanic, congratulations
Should definitely use a case saver for next time
How much to do the same repair on my 750?
Hi bro! Tell me if it is possible to install an engine from another Suzuki motorcycle in the fr600. If you know, tell me. I will be very grateful to you
No clue
My dad did that once to a car, put a quarter and slapped JB weld on lol
I would of never gotten that back together lol good job!
how long did it take to reassemble the engine?
Very nice work. Keep up the awesome content!
Excellent! You’re the man bro.
Hi friend,Can I remove the piston number 3 without disassembling the entire engine?
Only getting off the head of valves?
Yeah you need to pull heads and cylinder jug
Sabes qual o problema disso acontecer?
Nice job. Sweet sound of a runner.
At least 7 hours of video compressed down to 10 minutes! Another awesome video!
What manual was that? I have 96 SRAD motor collecting dust in my garage.
suzuki oem 06 600
You're one slick operator for sure
That was a very Rob Dahm outro. 👍
what is the total weight of the buggy?
Case savers my man,save alot of hassle.
I’ve been waiting for this one
On your gaskets ripping.. as long as it only rips towards the top, you can usually just silicone it and it will be fine and won't leak, because it only has to stop splashing oil from leaking.. But if the rip is in the bottom half where the oil sits, then you need a new gasket for sure, because it will leak eventually.
My boy with the rob dahm outro lol
now it will smash a bigger hole
Hmm, I would have tried to fix that cracked area as well. A vertical crack like that could be a stress point that will continue opening up. The way you stop cracks is by drilling a hole at each end, and then you can fill it in.
Mad skills and drive bro!
Good work
Pulled a rabbit out of you hat! Awesome, such heartbreaking location for a hole. Not an easy repair. Good job.
Great job bro 🔥👍✌️