1983 GS1100E project

[racerxnico]

So, as mentioned, I put it up on the work bench a few weeks ago. In the time since, I have been removing as many of the motor parts as I can to make it lighter and facilitate removing it from the frame. There have been a few complications so far. One of the cam cap bolts broke off below the surface of the head. I think it must have been broken before I started working as I just unscrewed the bolt. Didn't realize it was broken until I noticed that it was shorter than the others. It was in the locator tube in the lower right of the pic below (correction - this isn't the right pic - should have been from other side, but you get the idea).



I used a spring loaded punch tool to divot the top. Then I used an extra drill bit to increase the divot and give myself matching faces and used JB weld to bond the bit to the bolt. It was just strong enough.



The next problem was the head bolt on the exhaust side between the NO 1 and 2 cylinders. It was completely locked and rounded off when I tried to loosen. (center left in pic below)



After failing to find a nut extractor that would fit, I had to resort to a painstaking process of using a flex shaft extension on a dremel and alternate between a ball and side cutter bit to machine enough of the bolt away to get it off.



successfully removed head.



Have to go work for a bit, but will try to post again a bit later with next problem and suspected source of the "clunk".

[Baatfam]

Progress!

(And photos!)

[rphillips]

Awaiting the "clunk", looks like we should be getting nearer.

[racerxnico]

the clunk?

When inspecting my starter clutch I was surprised to find that two out of the three spring loaded pistons wouldn't come out of their respective recesses (bores) and the third wasn't doing its job (the spring had collapsed enough that it wouldn't actually push against the metal cylinder (roller).



It appears that the rollers had hammered into the metal around the recess enough times with enough force to deform it a bit and even crack it creating small edges that the shoulder on the pistons couldn't get by. I had to use the trusty dremel with flex shaft and ball cutter, while holding the piston down, to machine back the edge to get the pistons out.



eventually I was able to free them (you can see one out here and one still stuck in its bore).



While studying the part, I also noticed, aligned with the bottom of the bore, some deformations on the piece of metal that wraps the solid part. It looks like the pistons slapped back hard enough to dent the case (similar deformation aligned with all three bores).



The first thing I want to do is confirm that this should be a smooth round part with no "bump out" aligned with the bores. Does anyone have one they can look at? I was surprised (lucky?) the bike never gave me any starting issues. So this evidence looks like it aligns with the sound I was hearing (I hope I don't find other evidence of hammering further in, but who knows). My best guess at this point is that it was maybe a carburation issue that was causing it to maybe want to back fire or miss (shrug, not really sure if that makes sense) or possibly cam chain issue? Something that was making the crank want to rotate the wrong way for a millisecond, grab the starter clutch rollers and throw them back. Again, shrug. I would love to hear any theories, because what I've found certainly looks more like a symptom than a cause.

Oh, also, I am a combination of poor and cheap and reluctant to spend $180 on a new starter clutch. I'm going to keep my eyes open for a cheaper replacement option while I rebuild. If none come along, I'm going to try and reuse this one (it was starting fine before parked) with some new pistons, springs and shim (rollers seem fine). If it does end up giving me grief down the road it isn't so difficult to get to and replace later.

[rphillips]

I'd not seen this on a Suzuki, nor heard the clunk. A buddy has a CB1100F Honda & several yrs. back it started giving trouble starting. Starter would spin but didn't want to engage the crankshaft. Hit the button several times & it would finally start but getting worse. The Honda was about the same as the Suzuki set up. We got it apart & all looked good except the springs were all distorted, looked like they had been binding in the little slots & also they were about to push thru the outside of the hub. Bad cracks & hump where they were almost pushed thru. His rollers & little pistons were fine, just the springs & hub. New springs & a good hub from ebay & all has been good since. His never clunked, just had trouble engaging the crank. Glad you found it.

[racerxnico]

What is odd is that I never had a problem starting. It still grabbed and spun the crank just fine. I would never get the clunk at speed, but I would get it sometimes stopped at idle with the clutch pulled in and sometimes at lower revs in lower gears. Still very confused about what would cause it to do this. Thanks for the additional pieces of info.

[Grimly]

The search here is broked, but something will come up regarding 1100s and their starting clutches. They were notorious for kickback on starting if the battery and ignition wasn't perfect and it wasn't a sunny day in San Diego.
Some went so far as to install an ignition retarder for starting, which seemed to cure it once and for all.

[Rijko]

I have seen this starter clutch problem many
times.

Here's a good read on "The Clang"
https://www.theflyingbanana.com/starterclutch.htm

[Big T]

Good looking project

You should post this in the Projects forum

[racerxnico]

The search here is broked, but something will come up regarding 1100s and their starting clutches. They were notorious for kickback on starting if the battery and ignition wasn't perfect and it wasn't a sunny day in San Diego.
Some went so far as to install an ignition retarder for starting, which seemed to cure it once and for all.

Good to know. thanks

[racerxnico]

Good looking project

You should post this in the Projects forum

Yeah, I was thinking that. Wondering if there is a good way to migrate the thread or reference this one once I start posting there.

[racerxnico]

I have seen this starter clutch problem many
times.

Here's a good read on "The Clang"
https://www.theflyingbanana.com/starterclutch.htm

Very informative. Many thanks. Still curious about the fact that I wouldn't get it at starting, but once the bike was running. it does back up my theory that somehow the crank shaft was trying to rotate the wrong way and throwing the rollers back. Once I've got it back together (God willing), I'll make sure to confirm timing, cam chain tension, blueprinted carbs, and see if I still get it. At least if I do, I'll know where it is coming from and can trouble shoot from there.