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My first complete disassembly

  • Thread starter Thread starter R1reaper
  • Start date Start date
R

R1reaper

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Ok I have worked out my own motors for sometime, but I have never taken a motor down to the nuts and bolts, I have an 1981 Suzuki gs1100e. That needs the crank replaced. Which to me is a complete rebuild. Are there any special tools I will need. Other than a torque wrench, and assembly lube. I have a complete OEM gasket set. I got a while back. I don't have a new crank yet. I still have to find one. Any and all suggestions will be helpful. Thanks in advance guys!
 
Take your time and label/package everything as you go.
It always helps to thoroughly clean the exterior of the engine before you tear it down.
Follow the service manual for specs on wear and tolerances. Would be a perfect time to install new rings, hone the cylinders and change the valve stem seals.

Nic
 
you will need case sealant I think
and yes photograph and bag and tag everything
 
I have a lot of large plastic bags for bolts and I have three med size totes for parts. and oil to keep some parts lubed. I have 2 manuals for this bike. I figured since I was planning to take it apart this winter. Now is a good time as any to do a complete rebuild of the entire bike. Oh and I high jacked my Wife's tablet for photographs. I think I have everything I need I have to motor out of the frame and I am building the stand for today. Will keep you posted if I find or run into any problems.
 
FIRST thing you need, if you don't have one, is a Suzuki FACTORY shop manual. Not a Haynes, not a Clymer, a FACTORY Suzuki manual. You will need an impact driver as stated above, an air compressor & 1/2 inch driver air impact for the countershaft sprocket nut & clutch hub nut. You will also need an INCH pound torque wrench for re-assembly. This is all assuming you already have a good selection of metric wrenches & sockets. Good luck & feel free to call me at 714--356-784 five if you have questions or need help. I specialize in, race & build 1100s & 1150s.
Ray.
 
rapidray said:
FIRST thing you need, if you don't have one, is a Suzuki FACTORY shop manual. Not a Haynes, not a Clymer, a FACTORY Suzuki manual. You will need an impact driver as stated above, an air compressor & 1/2 inch driver air impact for the countershaft sprocket nut & clutch hub nut. You will also need an INCH pound torque wrench for re-assembly. This is all assuming you already have a good selection of metric wrenches & sockets. Good luck & feel free to call me at 714--356-784 five if you have questions or need help. I specialize in, race & build 1100s & 1150s.
Ray.
Click to expand...

Ok Ray where can I find a stock crankshaft for a 81 gs1100e, and what years and models are an exact match for a swap of I can't find an 81. The biggest problem I am having is finding a replacement. Also the starter clutch didn't do this the magneto/flywheel was the cause I think. The damage is so close to the end I don't see how the clutch could have don't it. I think I was the nut being loose let the whole thing slip. I even wondered if it could be repair?
 
I have the motor taken down pretty far, and I have found a lot of disturbing things like sand, rust and a 16th of an inch of carbon built up on the pistons. I have got the crank cracked open yet. I have all the case bolts out but it is really stuck together. I Have a parts bath that I will clean most of the smaller things, but I want to remove all the old paint from the cases. It is old and coming off everywhere. I know I don't have a lot of cash to pour into making the motor bullet proof. but want to get it back together as best as I can. and clean it up as good as possible.
 
Keep in mind that you have to remove the clutch hub & the 2 plates behind it that prevent you from splitting the cases. You will need the impact driver for this. There is also a 2 bolt plate in front of the countershaft sprocket that has to be removed. The ignition plate has to be removed also. Make SURE you have removed EVERY upper & lower case bolt & nut before you try splitting the cases or you WILL destroy stuff. Did you get the 2 bolts under the starter? Lastly, rather than taking a chance on an unknown, used crank, I would send your crank to John Pearson to have it rebuilt. You will have a good crank that will go the life of the rest of the motorcycle. Again, if I can help, call me.
Ray.
 
Ray I have it apart and the crank out. I know this is a little late to ask, but where about is the price range of having a crank rebuilt? I am a soon to be single father of two little kids. I am not trying to be cheap, I know the rule (you have to pay to play). I just can't through money at it. For me worse case is I will retro fit a newer motor into the frame. I am a fabricator by trade and steel is easy. I have already been looking at other motors to check prices. I would love to keep this bike stock, but in the end this has to be a small budget build. At least for now
 
I can't do that. I would have to save for months to pay for that. I will have to part this bike out, or something. I just can't do eight hundred for a crank. Crap I hate this. I have to look into doing something else. I was thinking 500 would be a lot never mind 800. I just can't I will have to figure something else out. Thanks to everyone that has helped me with the different problems with this bike.
 
OK Guys I have a new crank coming. Here Is what I have New Gasket kit, torque wrench. Impact gun. My 1981 Suzuki manual, New oil, And new crank coming.
Now guys what else do I need to do this rebuild.
 
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rapidray said:
FIRST thing you need, if you don't have one, is a Suzuki FACTORY shop manual. Not a Haynes, not a Clymer, a FACTORY Suzuki manual. You will need an impact driver as stated above, an air compressor & 1/2 inch driver air impact for the countershaft sprocket nut & clutch hub nut. You will also need an INCH pound torque wrench for re-assembly. This is all assuming you already have a good selection of metric wrenches & sockets. Good luck & feel free to call me at 714--356-784 five if you have questions or need help. I specialize in, race & build 1100s & 1150s.
Ray.
Click to expand...

For gods sake, don't tell chucky that a Suzuki manual is required!

do you have new rings and valve stem seals yet? You will want those also.
 
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What is the heck is valve stem seals???? I also picked up assembly lube. I was looking for something to reseal the case together. There is no gasket for that in the kit.
Also should I put the motor in the frame before or after putting the top end on. It is a real tight fit with the motor complete.
 
Valve seals, like these. http://www.ebay.com/itm/Suzuki-GS11...-16-/121033612510?hash=item1c2e2a5cde&vxp=mtr

don't necessarily use theses, just a reference for you.

to seal the cases use this http://www.z1enterprises.com/ItemDe...n=ThreeBond+Liquid+Gasket+1194&item=TU53-0395

if you have the OEM gasket kit it should have the stem seals.....

Personally I assemble the cases, install the cylinders then install in the frame. After that I put on the head and install the clutch and all accessories. The lighter the engine during install the easier it is.
 
Thanks for the links and if anyone thinks of anything else. Just post it.
 
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