Last year the rear came chain guide inside the engine of the 1981 Suzuki GS650L snapped in half causing the timing to jump and bend one intake valve. Since then I had been tearing down the engine to remove and replace the broken cam chain guide. It is fitting that as I start to rebuild the engine, the first piece to go back in is the new cam chain guide that I was able to obtain from eBay.
The next steps are just dropping the crankshaft back in, the main shaft, the output shaft, and the secondary driven gear assembly to the upper half of the crankcase.
The only pieces that are installed in the lower crankcase half before joining the two halves together are the gear shifting cam and the gear sifting forks. With the transmission set in neutral and the gear shifting cam in neutral the two halves of the crankcase can be joined together.
There are quite a few bolts and different sizes holding the crankcase together, so I did a dry fit first to remember where they all go…
Once that was figured out it is necessary to apply a liquid gasket to the mating surfaces of the crankcase. Since the manual is 27 years old and things change over the years, there is not a lot of agreement on which bonding product is best. I went with Honda Bond which had similar characteristics as the original Suzuki Bond No. 1215.
The only trouble I had with the Honda Bond was that as I was trying to squeeze it out of the nozzle it blew out the end seal of the tube. Got a little messy, but it still worked out ok. Just won’t have that tube for another use.
Once the two halves were lined up and the bolts torqued to specification, the crankcase was looking pretty good.
Next, I need to finish cleaning and painting the oil pan so that I can get that installed and flip the engine back over to continue on the top end.