Messages

1

Suzuki / Re: 1971 TM400 Engine Gasket Sealer

« on: December 07, 2015, 06:40:27 pm »

Thanks  for the replies guy’s. I guess I’m a little paranoid as I have not split the cases before. I have a can of Permatex spray copper and I think I will spray a light coat on each side of the gasket and call it good. The general consensus is with a gasket I really don’t need any sealer at all.

2

Suzuki / 1971 TM400 Engine Gasket Sealer

« on: December 05, 2015, 09:30:17 pm »

Hello All,

 I am assembling a 1971 TM400 engine and wondering if gasket sealer is recommended on the new gasket between the 2 case halves, if so what product? There are no major imperfections but a few very light nicks in the aluminum.  I am more concerned with an air leak in the crankcase than transmission oil leak. I have the service manual which is very vague at best. Thanks Randy

 

3

Suzuki / TM400R Question

« on: October 30, 2015, 06:59:16 pm »

I’m working on a 71 TM400R and on the clutch side there are what appears to be 3 holes filled with epoxy do you know what these are for? I want to heat the case to remove the crank bearing but don’t want to damage anything.. Thanks

4

Suzuki / Re: TM400 Manuals

« on: July 13, 2015, 04:16:09 pm »

I got the pressure/vacuum test done, the left crank seal leaked so bad that I had to use gasket sealer on it to get any pressure built up at all but after the sealer I pumped it up to 7lbs. it lost ½ lb. in 10 minutes so it passed but I will change all seals except for the right crank as I do not want to split the cases. The 1/2lb was lost at the carburetor manifold to head connection, the metal plate on the manifold has a slight bow in it as you can see in the photos the leak was so slight that the soapy water foamed like shaving cream rather than the larger bubbles that happened at the leaking crank seal.





The kick start return spring is fine and has good return tension so I am not positive as to why is was not returning when it was together and in the bike but it is difficult to really test it on the bench. A few things I did notice it had no clutch cover gasket  only gasket sealer, the kick start shaft seal garter spring was off of the seal and the seal deformed, and there was no thrust washer on the shaft between the kick start gear and the clutch cover as shown in the manual and the parts guide. The thrust washer is an obsolete part but I think I found one on line. I could get this back together and have the same problem of the lever not returning but I will correct what I found and hope for the best. Could a dry deformed kick start shaft seal cause enough friction on the shaft to keep it from returning?

5

Suzuki / Re: TM400 Manuals

« on: June 26, 2015, 01:43:14 am »

The main issue with this engine is the kick start lever is not returning which makes it a pain to try to get it running so I assume it is the return spring, can this spring be accessed by removing the clutch cover or am I back to splitting the cases?. It did run a few years ago when I bought it but not long enough to really determine its condition. I am now trying to make it a rider.

6

Suzuki / TM400 Manuals

« on: June 25, 2015, 04:20:48 pm »

TM400 Manuals



Starting to work on the TM400R engine and these manuals I have lack  detail compared to my Yamaha and Kawasaki manuals I have, are these all that’s available for this bike? I want to pressure and vacuum check the crankcase for leaks and replace all seals if needed what position should the piston be in to do this test? If I need to replace the right side crank seal I assume I am splitting the cases as the seal is behind the crank bearing? This is all new to me and I appreciate any advice. Thanks

7

Suzuki / Re: TM400R Flywheel Weight

« on: May 18, 2015, 08:30:36 am »

If it won't come off leave it on and time it by other means. I can explain how or if you are close do it for you.

Sleepy can you describe the timing process for me, my manual does not give a lot of detail on the process other than using a timing light but that is to check the timing while running and I am trying to get it running.

8

Suzuki / Re: TM400R Flywheel Weight

« on: May 16, 2015, 05:15:56 pm »

Thank you all for the reply’s and advice, I think at this point I will see if I can at least get it started and evaluate where I go from there. I did ride this a few years ago when I first bought it so the timing should be close as it sits. I just finished going through the carburetor which was leaking out of the overflow I tried setting the float level multiple times, tried a new needle and seat  and found the brass overflow tube in the bowl had split from top to bottom. I had another float bowl which solved that issue so tomorrow I will try to fire it up.

9

Suzuki / Re: TM400R Flywheel Weight

« on: May 15, 2015, 12:05:35 pm »

Well I’m at a loss as to how to remove this weight. I tack welded a piece of square stock to the weight so I could put it in a vise and with channel locks I cannot get the flywheel to move. Why are there 3 holes in the weight? They are about 1/8” deep but defiantly no screws in them, could there be rivets or pins in them attaching the weight to the flywheel? If so the 3 holes don’t line up with any holes in the flywheel so if they were to attach the weight to the flywheel you would need to thread the weight on drill the flywheel through the holes and drive the pins in and that doesn’t make sense. Are the part of the machining process when the weight was made? My last option is to take it to work and put a 3’ pipe wrench on it. Any thoughts here? Thanks

10

Suzuki / Re: TM400R Flywheel Weight

« on: May 14, 2015, 12:31:21 am »

Not the entire bike but I can see a waterline on the weight as the case had water in it at some point.

11

Suzuki / Re: TM400R Flywheel Weight

« on: May 13, 2015, 04:25:23 pm »

Got the flywheel off tonight but the weight is still connected I’ll try to separate the two at some point, no screws in the 3 holes. Both the crank end nut and the threads on the flywheel look to be RH threads meaning righty tighty lefty loosey , am I correct on that? The flywheel puller for this bike is listed as 30mm x 1.5mm Right Hand Threads so why does the article I posted above say to install the weight counterclockwise?

12

Suzuki / Re: TM400R Flywheel Weight

« on: May 13, 2015, 09:44:43 am »

  but are there grub screws in those 3 little holes which lock it on to the rotor. 

Man I hope not but I'll need to clean out all the rusty crap and take a look inside. if there are screws in there it's going to be a job to get them out if at all.

13

Tech Talk / Re: Keyster Carburetor rebuild Kit

« on: May 12, 2015, 04:42:06 pm »

Thanks guy's

14

Suzuki / TM400R Flywheel Weight

« on: May 12, 2015, 04:40:10 pm »

Hi Guy’s 

Does anyone have any experience or know about the aftermarket flywheel weights on a 1971 Suzuki TM400R. I started working one and assume they thread on the stock flywheel so once the nut a lock washer are removed it should thread off counterclockwise? I want to pull everything off to replace the crank seal and clean it up. I also assume that sense the weight covers the timing marks on the flywheel the weight needs to be removed to check the timing. I have included a photo of the weight on the TM400 and one without the weight on another TM400 I have,  also a photo from an old article about installing the weight as it looks very similar to my set-up. Any thoughts or input on Weight removal? Thanks

With Weight


Without Weight


Article Photo

15

Tech Talk / Keyster Carburetor rebuild Kit

« on: May 09, 2015, 05:13:56 am »

 Has anyone used or have any feedback on the Keyster Carburetor rebuild kits, I have a Mikuni VM34SC on a Suzuki TM400R and their kits seem reasonable compared to buying individual parts from Sudco but if the quality is poor I would rather spend the extra money for the genuine Mikuni parts. Thanks