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82 1100e Engine Rebuild ???

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After several years of inaction I've started the process of replacing the lower cases on my 1100. I discovered that the cases had a leaking micro stress crack near the front motor mount. The damage wasn't discovered while the engine was being rebuilt so I have a well built engine with 1166/HD clutch hub/cams and welded crank with bad case.

I'm probably in over my head but I've got the time and want to learn.

I'll start a project thread soon when I have more photos. I've started assembling the new lower cases but haven't torn into the old engine yet.

I have a set of NOS silver cases with no serial numbers. It came with a oil spray nozzle already installed in the upper case.

Why is there only one nozzle? Seems like there should be one for each bearing. I plan to install high volume 750 oil pump gears, do you still use the nozzle with the higher flow? Thought I read something about possibly not using it.

On the spare transmission I plan to use, three of the four outer bearings have a locating pin sticking out that gets held in place by the assembled case halves. The manual says they should all have the locating pins. The bearing that doesn't is the small bearing on the clutch side of the output shaft. I assume they prevent the bearings from spinning. Are they critical? The transmission in the bad case engine probably has the bearing I need.

Lastly what labor saving steps can you suggest? Should I leave the pistons on the crank?
 
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Resolved one issue. I had bought new a left hand bearing P/N 20041 for one of the shafts. It is identical to, and supersedes the right hand bearing P/N 20044, which is missing the pin. So that issue is taken care of.
 
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If you run in to any road blocks let me know. I have lots of engine parts.
Oh and the pistons will not clear the upper case. Been there tried that.
Do you have an engine stand?
Always split them upside down or the transmission falls out.
Where are you located?
 
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chef1366 said:
If you run in to any road blocks let me know. I have lots of engine parts.
Oh and the pistons will not clear the upper case. Been there tried that.
Do you have an engine stand?
Always split them upside down or the transmission falls out.
Where are you located?
Click to expand...


Chef I'm right next door in central New England. Thanks for the clarification on removing the crank with pistons. I guess I'll at least be able to leave the rings on.

Hopefully I've got most of the components. I don't have an engine stand. I'd like one but I have absolutely no room left. Just having two tables with all the parts and pieces laid out is leaving very little room.

I have the upper case upside down now waiting for the crank from the other motor. Beside it I have the lower case with the trans loosely fitted. I guess I'll have to make some type of wooden frame to hold the lower case off the table to allow for the con rods to poke thru.

Check ouit the transmission photos and tell me what you think of the marks. I got this transmission with some used cases from another forum member. I was actually more interested in the output shaft, which seems to be in decent shape. Hadn't noticed the marks till I took the pics. I have my original transmission in the assembled engine but it does have 106K on it. The engine builder thought it was good enough to use. Had hoped to use the one in the pics.









 
Any opinions as to whether it will be as smooth as stock (being that the 1150, I'm told, vibrates a lot more than the 1100)?

Good luck with the build, and keep those beautiful pics coming. I'd come and visit, but the bridge is out! :biggrin:
 
Rob S. said:
Any opinions as to whether it will be as smooth as stock (being that the 1150, I'm told, vibrates a lot more than the 1100)?

Good luck with the build, and keep those beautiful pics coming. I'd come and visit, but the bridge is out! :biggrin:
Click to expand...

Rob, there are several members with this set up on an 1100 like Posplayr and I haven't heard anyone mention vibration as a problem. One theory on the 1150 vibes was it resulted from the bigger wrist pin's but who knows for sure.

I hate to just keep posting pics cause then the experts get all confused and bleary eyed and never answer my earlier questions but if you insist.







You're only a virgin case once.
 
I need a side picture of the dogs on gear two. Any what appears to be tool marks on them? It's an obvious defect if you know what to look at. Once you see that you know what to look at on the other gears.
All used transmissions for these old GS bikes will have some sort of mark unless it is SUPER low miles.
 
Rob! This whole 1150 vibration has turned into your opinion and not based on fact.
 
Rob S. said:
I'm still a virgin, but I believe that's the clutch cable holder, the bottom case and the top case.

What about the whole bike?
Click to expand...

The rest of the bike was pretty much complete when I got rear ended by a 3/4 ton GMC. The champagne body work survived well but the frame was tweaked.

This is also how the engine cases cracked. Don't have any good pictures with the replacement 83 frame and wheels powder coated but heres the two sets of body work on the 82 frame pre-disaster. GMC's insurance company paid me well so I decided to build the engine. Got it all put back together and found the leak. Can't blame the builder. Neither of us saw it as its pretty microscopic and doesn't weep till the engine is warm.







I've been procrastinating for years on putting it back together but I have other bikes that have been soothing my passion.

It's Easter, time for a second coming.
 
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chef1366 said:
I need a side picture of the dogs on gear two. Any what appears to be tool marks on them? It's an obvious defect if you know what to look at. Once you see that you know what to look at on the other gears.
All used transmissions for these old GS bikes will have some sort of mark unless it is SUPER low miles.
Click to expand...

Gotta charge the camera battery. I'll post them a little later today.
 
isleoman said:
Gotta charge the camera battery. I'll post them a little later today.
Click to expand...

Chef, Here some shots of what I think your interested in. The pictures show up the nicks more than seeing it in person.

I'm assuming the nick at the bottom right edge of the dog is the concern.







Back side is smooth.

 
I went on Ebay and was looking at the transmissions for sale just to get a reference and most looked much worse than this transmission. I also notice no one on Ebay wants to show you a good shot of the dogs.

Don't have my assembled engine apart yet to see what my old tranny looks like.

I'm training myself on using a degree wheel and dial indicator by checking the engine builder's numbers before I open it up. I did notice the adjustable sprockets are set at 21 pins.

Any tranny experts want to weigh in? Does this unit look ok?
 
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I have good transmissions and a bad shaft with the #2 pressed on. I'll try to get over to the shop to take pics of both.
The one I have on eBay is good.
 
Chef, It's a little difficult to see in your pic. Just to confirm the dog is the dark block on the side of the top gear and the rounding of concern is on the vertical outer leading edge, if its rotating clockwise? The dog in your photo seems to be rounded along the top horizontal edge as well.

Does the rounding in the pics I posted worry you? On my gear it seems to be a small nick on the lower 1/2 of the leading edge.

Thanks for posting up the pic.
 
As long as you still have a ledge and have not worn out the squared edge.
I took over ten pics and only had on come out decent.
I should of brought my good camera.
 
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