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Discussion Starter · #1 ·
ok, so i know without having a gauge to go off of this may be me over reacting... but... i was on a 30 mile run into town the other day and i noticed when i came to the first stop light that my idiot light was on at an idle, reved it a few times and it went off... till the bike got under 2000rpms them it came back on. its unknown what the pressure is as i havent been able to afford an actual gauge yet which is where i really need to start at for a decent diagnosis. running 20/50 GTX in it. Any common issue or problems i outta be aware of with this bike that i didnt know about before? I know of the pump O-ring issue and replaced them already and its still doing it. any possibility of it being a bad sensor, bad pump, or spring weak in the high pressure valve on the pump? any suggestions would be great. I'm just praying its not a main bearing... but, no shavings in the pickup, filter or pan(just pieces of clutch... but not enough to block the pickup... what i consider a "normal" amount.)
 

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You mentioned the oil pump o-ring issue so I'm assuming you have a SOHC. If so, those o-rings were gonna be the first thing I was gonna suggest. In all honesty, the idiot lights are not all that trust worthy, but they ain't all bad either. It may just be time for an oil change. These old airheads are pretty hard on oil. I dump mine every 2K miles in hot weather. Filter every other time. Do you have,the adapter for the upper oil gallery to mount a gauge? If not, there's enough meat in the stock plug to drill and tap it for one. You can save a few bucks that way.

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Oh, if you saw pieces of clutch you need to check that ASAP! The outer plate is famous for delaminating on these (still assuming you're rocking a sohc) and if left unfixed will dig up the soft aluminum pressure plate FAST! Don't let that go unchecked. You can get that plate as a single from Barnett for $15. It has different oil shed grooves than stock and seriously improves the feel of the clutch. It'll chatter like a bitch, but...clutch.chatter is sexy :D

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I R smart.
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562 Posts
Discussion Starter · #4 ·
Yeah I plan on looking into the clutch issue soon, have heard a rumor around town they my oil lines have been sabatoged by this skinny little tweeker who aparently has a deathwish. so gonna check into that, havnt seen any leaks in my lines though, alos yeah is a SOHC 836cc. And the oil thats in it only has like 300 miles on it. Im pulling the oil pump to see if there have been any objects thrown in my oil tank than may have been sucked down in my pump. But good call on the oil cap drill/tap project, will be one i start soon now. and seeins how i have 4 or 5 of these engines laying around, could always just pull the plug from one of the others and start in on it. Thanks again, will keep posted on my findings.
 

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Cool. I'm working on putting together an 836 myself. What cam are you running? And whose pistons did you use? I'm having a hard time picking out a cam. I'd really appreciate some advice. Catalog descriptions of cam characteristics dont mean squat to me. I'd rather hear it from the guy behind the handle bars,than the guy behind the computer :D
 

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Discussion Starter · #6 ·
still has a stock cam in it for now. but they are a wiseco piston kit. ended up being bored out after someone else toasted the original cylinders and head on it. I have a 69 here that has a cam in it, but i have never ridden it.
 

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Discussion Starter · #7 ·
Heres the original pull apart to show the conditions of the O-rings that i changed last week.

This one was never installed correctly.





So, after giving myself a few day cooloff period before touching the bike again. pulled the pan back off, pulled the pump and got it apart. the problem was pretty self explanitory.



Faces are scarred.


Rotors are wasted.






So, cleaning the entire system and tank out, and pulling the pump off my parts bike and cleaning it out and gonna swap it on after changing the O-rings again.
 

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Discussion Starter · #9 ·
And The stupid light still comes on under 1500 RPMS when its warm now, but its better than it was. I have a thought that maybe the odds are that the filter is clogeed and the bypass isnt opening as much as it needs to at an idle may be a little high. Also beginning to wonder if my fuel soaked oil is just already burned up and wasted. its already black. so gonna try an oil change next. Also im not sure if the Orings i changed are the right ones either. honda calls for 15X2.5mm and the ones i put in there are 15X2.0mm Not sure if that extra .5mm in width makes a huge difference but. who knows, it is trying to hold back 70+ psi of oil pressure. If not, im back to square one and thinking the worst... that im losing a main bearing and have to split the case. I also read something somewhere that the head studs on these stretch and need to be retorqued or it wont hold pressure, but i also read if that was an issue, the oil galleys on the back of the head would be leaking from the head gasket onto the back of the engine. so IDK... its pissing me off. I just wanna Ride. :'(
 

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What kind of oil pressure does it run at highway speeds? Not trying to be a jerk but you gotta a gauge on that thing or you'll be chasing your tail for a long time.

Hell, you might find your oil pressure is spot on and only the idiot light is acting up.

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Discussion Starter · #11 ·
yeah hopefully buying one tomarrow, i took the sending unit out and smashed it with a hammer to make myself feel better. replaced it with one out of my parts bike, seems to be working now, or ive gone from one extreme of bad sensor to the next. but. this one actullay shuts off without the bike even being running, just cranking the starter for a few seconds and the light shuts off. sat here in the garage with a roll around swamp cooler on the bike for about 15 minutes and was babysitting the bike to make sure nothing bad seemed to be happening, i shut the bike off, and the oil pressure light stayed off for about 3 seconds after turning the bike off. felt confident enough to take a small backpack full of tools (7,8,10,12,14,15,16,and 17mm wrenches and sockets, a ratchet, an extension, a big and small crecent wrench, a pair of pliars, a pair of needlenose, a flashlight, quart of oil, #2 and #3 philips, 2 flatheads, and a couple energy drinks) on a 20 mile ride with me, to see what would happen, climbed up a pretty good grade and pushed it as hard as i felt comfertable pushing it. got to the top and stopped, no oil light, shut the bike off, came right on. started the bike back off, it shut off, cycled that about 4 times. hung out and looked at the view for a bit, then took off and came back home to get yelled at by my girlfriend for bing gone and out of cell phone range. so, my day is complete... girlfriend is pissed off, bike is running right, my goals for the day have been achieved :D
 

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Discussion Starter · #13 ·
thanks, yeah its the cylinders off my suzuki, we figured out that monster cans fit in them perfectly. took a good 15 minutes of resizing it to get it small enough to use it. it amuses me and im pretty proud of my efforts.
 

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Discussion Starter · #14 ·
Well, got my 2-1 exhaust cleaned up and gonna put it back on and take my drag pipes off, oiled the chain and readjusted it again for what seems like the 100th time already, changed the flasher relay to one that blinks at a lower voltage, started to try and install LED turn signals to try and save a little bit of load till the cheap ass things snapped in half.(pics to come on our main forum build) so put the stock ones back on. cleaned up a little more of the garage and cleaned the house, been a pretty boring but constructive night. trying to get back on a day schedual, not sure how much longer im gonna make it. just thought i would pop in and mark my progress for the day. Ride safe all, and remember seeins how nobody is gonna look twice for you, look four times for them getting ready to do something ignorant.
 

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What kind of chain you got dude? These bikes aint the pastest,but they still work a chain pretty good. Harder than alot of people would think. I bought some lighter duty chains (low tensile strength) and they stretched real fast like you described. I was adjusting every couple hundred miles and alot times I ride more than that in a day. Sucks having to ride with that big axle wrench cuz you know your chain is stretch before you get home.LOL

I've been running Bikemaster 9,600 tensile strength chains lately and they do real good for the price. A 530 o-ring runs about $70 at that price. I got one on the chop with only 1k miles on it. Another on my cafe with 3k on it. Neither one has stretched ever. Not even initial stretch you would expect. I got another buddy who runs one on a CB750 matic that has 8k miles on it and has never,ever adjusted his either.

I know money aint growing on trees,but dont mess around with a cheap chain dude.You can get hurt real fast,real bad. Just putting it out there.
 

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Discussion Starter · #16 ·
an ACME 60 series that im pretty sure was ment for industrial use. he picked it up like 20 years ago and had some sprokets fabed up in the machine shop he worked at, they where originally on a chopper, original one on my bike was totally wasted. so i stole the one off the chopper and had to pop like 7 links out of it to get it to fit.

Original chain... made a cupholer out of it.


CnC machined aluminum rear sproket.


Never used 60 series chain that sat for like 20 years.
 

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Well, I don't know anything about those types of chains. But if its stretching that fast you know what that means. If you've had to adjust it several times chances are it'll start hooking your sprockets pretty soon. Does it lay nice and tight where it wraps around the rear sprocket? If you can pull it away from the rear sprocket at the 3 o'clock position then its grown too long already. But you probably already knew that.


Hey dude. When you gonna post some pics of your engine sickle??

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Discussion Starter · #18 ·
Well the engine build happened before i had a camera or cell phone so till i take it back down i have nothing. I dont really see a point at the moment of taking pics of my dirty oily engine either cause i havnt gotten around to cleaning it back up after changing the cam cover gasket last time(had to go fishing for a tappet nut that backed off). thinking after i got my other suzuki that im gonna tear it back down again and swap the cam out with a DP-117. same place the piston kit came from at dynoman.net. And this chain wasnt prestreched and only has like 800 miles on it. its not streched out of spec yet and im having trust issues with it anyways and check it EVERY time i get home. really it just seems like i have adjusted it hundreds of times cause i had to constantly adjust the old one practicly after every 2 rides. decided to pull it off when it started jingling like christsmas bells even after oiling it. Last thing i wanted was to get tagged with a chain at 80 mph.
 

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I R smart.
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Discussion Starter · #19 ·
But on another note i do like the final drive ratio on it. i would mention the tooth count but the fact that its a 60 series and not the normal 50 the numbers wouldnt match anyways. but being able to cruise at 80mph at about 4800rpms is nice. The takeoffs do suck though, still getting used to it and have stalled it a number of times at stoplights when im 2 up. but with the 836 kit, its amazing the pull it has for an old bike.
 

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Discussion Starter · #20 ·
The gauge i ended up getting with the sending unit for less than $50.

 
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