well put it back together ran for maybe 2 min and then the jug blew off the top of the cases busted right side case there is about almost a half an inch gap between them why did this happen I am pushing it back in garage till I figure this out or when u tell me what's wrong

 

What year is the motor/cylinder? I had a a 87 with all 87 parts top to bottom. It blew a head gasket even with oversized studs and once blew a seal out on the crankshaft. I didnt have any problems like yours but didnt log that many hours. Wasnt good for my type of riding so I mainly just took it out to show off for a while every now and then. The one I sold to my freind was all 87 but a 90 top end. I think the little intake hurt him bad for power but he ran the crap out of it for two years with no trouble but one wore out piston and stuff rattling loose a lot. Unless your drag racing the answer might be a later model cylinder.

 

it is a 87 bottom end with a brand new 90 jug got it from suzuki (top end) do you think it is trashed top end i am going to tear it apart tomorrow i hope it is not messed up i just spent 1500 last month and 600 month before that wife is not happy she told me to sell it but no way piston was tight i just cant see it jamming in there right before this base gasket blew out same thing ran for 2 min then water started coming out so shut it down and put new gaskets in it piston had some light scars on it so i sanded it with 800 then 2000 grit to remove scars thought they came from air leaking in it cylinder walls were fine no sign of anything wrong i am stumped never had this happen one thing i did not have air filter on it but i was just sitting in garage with it idling when this happened any ideas

 

I wish you could speak/type a little better. You guys come on here all the time asking questions and we all would like to help but cant tell what the heck youre talking about. In your first post you said "the jug blew off the top of the cases busted right side case there is about almost a half an inch gap between them". My original interpretation of that led me to believe there was major devastation. Next post it sounds like you just blew gaskets. ?????????????????

Water may have entered the cylinder while it was running and somehow caused the the scaring on the piston but if it only ran for 2 minutes then air was not the problem. If the scaring is only on the top of the piston and the rings, cylinder and sides of the piston are undamaged than it didnt likely jam or get tight.

 

sorry I am chicken pecker on key board! When you are sitting on bike and you look on right hand side that's where it blew off the whole jug lifted up like there were no bolts in it and it stayed up you can stick your pinky finger in it it ripped the 2 front bolts out the ones on each side of header pipe and on right side it just ripped those ones right through case left side really can't see header is in the way but just alittle bit ago I went in garage to look at again well I pushed on kicker and it moved piston went up and down I could see it through gap how is water going to get in there everything was tight before I put in and its all brand new never used head and jug

 

i put a picture of it on my page you will have to look at my pics it is #12 i dont know how to post it on this page but thanks

 

Just a shot in the dark here , but when you installed the connecting rod and piston when you did the top end replacement ; you could've installed the piston and rod in the wrong possition you must pay close attention to the way the connecting rod and piston come's apart to make sure they go back in the same way it was removed !

On most piston's there is a reference mark that must be possitioned the same as it was removed , and if you removed the connecting rod it's even more critical ; i don't know how far you went into the crankcase but i have seen this with just the piston and wrist pin !

I've seen just this slight alinement of the piston alone do major damage to both the bottom and top end many time's in the past , i alway's take photo's and note these proceedure's on any type engine i've ever rebuilt ; without knowing how far you went into the overhaul it's hard to say for sure !...........

 

Seems like the more severe problem is the cyinder pulling up from the crankcase. I cant tell for sure but it almost looks like it broke part of the crankcase where the cylinder bolts down in the back, like the fron bolts pulled out but the back didnt so it broke loose part of the crankcase hwere it mounts up. If that so than its an even worse problem. There may have been nothing wrong with the piston, it may have got those scars as a result of other problems. I have 2 ideas on why the cylinder pulled loose and it could be both of them. One - if you blew a gasket and water filled the cylinder it may have caused the cylinder to pull loose and could also have bent the rod. Two- on mine it had studs in the crankcase and the cylinder was held down by nuts threaded onto them. On yours I see a bolt that may or may not have been long enough, might have been long enough but wasnt with the 2 lockwashers and also if the original stud was not there and replaced with a bolt it would make me wonder if the threads in the case had allready been damaged.

I would focus most of my effort on why the cylinder pulled loose and if it can be fixed.

 

i did noy take bottom apart when i got bike it did not run i dont know if they took it apart and piston is where it should be i know that much it has mark on it for exhaust and it points towards front the only thing that i was not sure of was top head gasket it had large holes and small round ones lets say that the head had all large holes and the gasket had one half was large and the other side had small round ones i was not sure how to put it lagge ones in front or rear gasket also had a tab that stuck out but if i tried to make it stick out in dead front center gasket would not line up correct so it is off to side alittle

 

you could see where somebody put a heli coil in it cause threads were stripped out on that one back bolt but where is the water coming from then