Is there a lower end rebuild kit / shopping list??

[Guest]

Hi. I am re-newing my '79 GS 1000E and I need to repair or replace my engine cases as both the upper and lower cases were damaged (points cover smashed and the 3 screw / bolt holes ripped out) in a tip over 15 years ago and the JB Weld repair is no longer holding the three screws / bolts. So I have elected to replace the engine cases with a good set that I got on e bay. I am confident that I can do the work but before I get in there I want to order everything, short of crankshaft and transmission bearings that I might require.My bike has been babied and well maintained so I am reasonably confident that bearings and rotating pieces will be fine. I am thinking of seals, o rings, dowel pins, gaskets that may be damaged getting them out of the old cases.(Are there needle bearings that are pressed into the cases?) By any chance is there a Shopping List or rebuild kit that I can source - sort of one stop shopping to avoid poring over fiche parts lists and then potentially missing some parts and having to wait on 2nd parts shipment? it can take 3 weeks for parts to get here to the Great white north. Thanks

[SqDancerLynn1]

There is no set rebuild kit. I would get a complete OEM gasket set. The rest you need to take everything apart & clean it and examine it. before you will know what you need. How many miles on the motor ??

[Graham]

Replace all gaskets, o-rings and seals. Check the bearings, springs and gears for wear. Check piston, rings and valves since you’ll have the top off anyway. Your bike will make your shopping list.

[Prairiesailer]

The engine has 53,000 Km / 33,000 miles and in my opinion was running perfectly before being stored 5 years ago. So I am going in with the assumption that pistons, rings, rod free play etc. is all within spec. So was hoping that I could order all of the parts that I think will be damaged by taking them out (thinking of seals) and do the disassembly / assembly in one day. IF I get in there and find considerably more wear than I am anticipating, well then a whole other decision process will kick into play. I already have the engine out and have had the valves cleaned up and valve guides replaced etc. Also have bought an OEM gasket kit. I also have had the carbs professionally cleaned. But,I get the message that there is no "one stop shopping" so I'll spend the afternoon going through micro fiche and develop my own shopping list. Thanks for your advice folks.

[7981GS]

Have you looked into finding a running engine or at least one that is not damaged?
Surely, it would cost much less in time, $$$ and trouble.

Daniel

[Prairiesailer]

Wow!
Daniel, looking at the list of bikes that you own makes be believe that when it comes to renewing the GS, YOU certainly know of which you speak. A couple of days ago I did toy with the idea of complete engine replacement and did a quick search on e-bay, found a couple of likely engine suspects, in the US, and then added the freight costs for such a heavy lump. Let's just say that the landed costs, coupled with the possible lingering doubt as to the reliability of an unknown engine have reminded me that I really do enjoy the wrenching just as much as I like the riding. So I think that I will stick with rebuilding my engine. At least a couple of the GSR members have thoughtfully posted albums of their own engine rebuilds so I do have others' work that I can follow.
back to studying the micro fiche. So far the shopping list isn't too long - a couple of crank shaft seals and one needle bearing, but, I am not done.

thanks,
Ian

[Nessism]

There is no "kit" available, other than maybe a gasket kit. You need to pour over the parts fishe and order everything one piece at a time. OE gaskets are the way to go, but not cheap.

[850 Combat]

I haven't seen the damage, but changing cases over stripped timing cover bolts seems extreme. I know there is a "magic pud" product for that from Locktite/Permatex. and there are also helicoils, as well, of course. Is 1sn't solid enough to drill it out and retap it? I would at least try, but then I may be lazy and cheap. the OEM gasket set alone is a hundred or so dollars.

[Prairiesailer]

Well I certainly agree that case replacement would be an extreme fix for stripped threads for the timing cover bolts. But it is more than stripped threads. When the bike was knocked over the timing cover itself was shattered and the bolts tore out "chunks" of the upper and lower cases where the bolts were tapped into. The timing cover was simple to replace and I did a pretty good repair of the ripped out chunks with JB Weld (Epoxy type system) that lasted for a good long while but eventually the vibrations wore out the threads in the JB Weld. So, I saw a good deal on cases on Ebay, already had the engine out, and for me 50% of the fun of Motorcycles is the wrenching - so away I go with a rebuild.
I am sure that I will have more questions of the GS Resources community as I get further into it.
Thanks.

Ian